Improvement of Hazard Analysis Critical Control Point system through layout design, Critical Control Point validation and accelerated shelf life study

Hazard Analysis Critical Control Point (HACCP) is an internationally recognized certification scheme for food safety assurance. Despite the acknowledged economic benefits to the Small and Medium Enterprises (SMEs), the HACCP implementation is still limited in this sector with burden of inadequate food safety knowledge, financial capability, and access to experts and technical supports. This research study aimed to improve the microbiological safety of a local Malaysian product, frozen crispy chicken curry puff (FCCCP) and the HACCP documentation of the food SME in attaining requirements for HACCP certification. To initiate the study, layout design was developed to improve the food safety of the product. The Facility Sanitary Design Checklist was used to evaluate the hygiene zone, the flow of workers, and material flow throughout the layouts. New layout design was developed using activity relationship analysis. Seven HACCP logic sequences were then improved through technical plant visits and onsite observation, HACCP documentation reviews and microbiological sampling. Next, ground chicken was inoculated with a 2-serovar cocktail of Salmonella Typhimurium and Salmonella Enteritidis to a target concentration of ~7 log of cfu/g. The survival of Salmonella sp. during cooking validation was analysed at internal temperatures; 60, 67, 74, and 81 ℃. The thermal inactivation of the Salmonella was determined at 55, 57.5, 60, and 62.5°C using a temperature-controlled water bath. An accelerated shelf-life (ASL) study was carried out at–18, –8, 2 and 12 ℃ within 12 weeks to estimate the microbial shelf life of FCCCP using the Arrhenius equation and Q10 concept. The result of the study showed that the establishment of distinct hygiene zones of the existing layout was 38.5% and worker and material flows were 22.5%. A new layout was proposed where the arrangement was in the order of product flow based on closeness rating. The new layout scored higher in hygiene zone application (78.8%) and worker and material flow (90%). Seven HACCP logic sequences were improved, and the cooking process of FCCCP filling was determined as a CCP related to Salmonella. Validation of the cooking process demonstrated no survival of Salmonella sp. at an internal temperature of ≥ 74 ℃ after 23 minutes of cooking which eliminated ≥ 7-log cfu/mL Salmonella sp. as per acceptance criteria for process validation in cooked poultry products. The D-values of the Salmonella were 29.31, 7.25, 5.41, and 1.33 min at 55, 57.5, 60, and 62.5°C, respectively; and the z-value was 6.05°C. In the ASL study, yeast and mould count had the highest correlation and the estimated microbial shelf life was 30.5 months at –18 ℃, 6.86 months at –8 ℃, 1.72 months at 2 ℃, and 0.47 months at 12 ℃. Q10 was found to be 4.45, 3.99 and 3.62 at -18 to -8 ℃, -8 to 2 ℃, and 2 to 12 ℃. Salmonella was not detected in any of the studies. Findings from this study presents an insight into food safety towards the implementation of HACCP principles in Malaysian food SMEs. The findings provide practical information and technical guidelines which can be used as supporting documents in fulfilling HACCP requirements, subsequently promote HACCP adoption among SMEs.

Text 122569.pdf Download (1MB) Official URL or Download Paper: http://ethesis.upm.edu.my/id/eprint/18614

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