CCP-HACCP For Instant green tea powder

MINISTRY OF EDUCATION AND TRAINING NONG LAM UNIVERSITY – HO CHI MINH CITY FACULTY CHEMICAL ENGINEERING AND FOOD TECHNOLOGY Class DH18TP  INSTANT GREEN TEA POWDER INSTANT DRINK December 2021 Ho Ch.

INSTANT GREEN TEA POWDER

INSTANT DRINK

December 2021 - Ho Chi Minh city

GROUP 5 - MEMBERS

2

TABLE OF CONTENT

TABLE OF CONTENT 2

INTRODUCTION 3

HACCP TEAM 4

PRODUCT DESCRIPTION AND INTENDED USE 5

FLOW DIAGRAM 6

PLANT LAYOUT 7

PROCESS STEP DESCRIPTION 9

RISK ASSESSMENT AND CCP, OPRP DETERMINATION 12

HACCP PLAN 18

OPRPs PLAN 19

DISCUSSION AND CONCLUSION 21

1 Discussion: 21

Non-CCP hazards: 21

CCP hazards: 22

Non-OPRP hazards: 23

OPRP hazards: 23

2 Conclusion: 25

REFERENCES 25

3

INTRODUCTION

HACCP is an abridgment of the Hazard Analysis Critical Control Point system, which

is tantamount to food safety management Essentially, it is “a system which identifies, evaluates and controls hazards which are significant for food safety’’ It is a system that gives confidence that food safety is being controlled effectually The hazards that need

to be analyzed and controlled are biological, chemical, and physical hazards from raw material production, procurement, and handling, to manufacturing, distribution, and consumption of the finished product or anything that could go wrong regarding product safety and implements controls subsequently to ensure that the product will not cause harm to the consumer

OPRP as a control measure identified by the hazard analysis as necessary to control the likelihood of introducing food safety hazards and contamination or increase of food safety hazards in the product or the processing environment OPRP is definite action relating to the process, although not being critical for food safety, but they are essential

in reducing the probability of specific hazards occurring

Turning green tea leaves into instant green tea powder is a complicated process that included many stages of preparing as well as processing To achieve good products

quality and food safety and hygiene Mainly hazards biological from E Coli bacteria,

Salmonella, Coliform, etc and other physical hazards, chemistry, allergies need to be

minimized to the maximum Research plans for the Hazard Analysis, Critical Control Point (HACCP), and OPRP systems for pre-processing and processing at instant green tea powder factories need to be discussed, researched, implemented, and focused, followed clearly to minimize the unfortunate threat to products quality

4

HACCP TEAM

No Name Position Responsibility Skill/ Experiences

leader

BSc - Food Science MSc - MBA

10 years of experience GMP, HACCP, ISO certificate

BSc - Food Sci & Tech GHP, HACCP training

3 years QA experience

3 Jena Production Manager Committee

BSc - Food engineering GHP, HACCP training

5 years QA experience

BSc – Chemistry GHP, HACCP training

4 years QA experience

BSc - Engineering GHP, HACCP training

5 years QA experience

6 Pine Packaging supervisor Committee

BSc –Control Engineering and Automation GHP, HACCP

5 years of experience

7 Rina Raw materials

reception manager Committee

BSc -Food Science HACCP certificate

3 years of experience

8 Thomas AG Supervisor Committee

BSc - Food Sci & Tech GHP, HACCP training

3 years QA experience

9 Xuan Warehouse operative Committee

BSc -Food Science GMP, HACCP, ISO certificate

4 years of experience

5

PRODUCT DESCRIPTION AND INTENDED USE

1 Product name / Group product Instant green tea powder

4 How the product is to be used - 1 teaspoon powder with 200ml warm water

(60 - 80℃), stir well to mix with sugar, milk to drink better

- Make a face mask

5 Packaging (net weight, etc.)

- Net weight: 40g (2g x 20 sachets)

6 Shelf-life and storage condition - Shelf-life: 2 years

- Storage: Please store tea powder in a dry place

at room temperature and keep away from direct sunlight

7 Where the product will be sold - Supermarkets, markets

9 Special distribution control

No physical damage, avoid placed with high temperature or humidity

10 Consumer group All ages except children under three years

6

FLOW DIAGRAM

Information: Tea powder is packed in aluminum foil sachets with a

weight of 2g per sachet (20 sachets per box) The product contains 100%

pure green tea leaf powder, does not have any allergen and is suitable for

all ages except children under 3 years old This product can be used to

make soft drinks (1 teaspoon for 200ml warm water) and can be used as

a mask (mixed with yogurt, honey in a 1:1 ratio) Nutrition information,

serving size, EXP and ingredients are declared on label The storage

condition: cool, dry place and avoid physical damage

7

PLANT LAYOUT

To avoid cross-contamination in food manufacture, the factory must be designed and

organized in accordance with HACCP and must adhere to the one-way rule from input

materials to final products As a result, the factory is divided each level of cleanliness

into production and non-production areas

I Production area

Reception raw material (incoming materials and raw materials store): Raw products

are in the proper conditions (avoid places with high temperature or humidity) and

method so as to maintain quality and reduce loss of the material during storage

+ Incoming raw materials where the company imports raw materials including tea

leaves, water, paper box, and aluminum foil sachet from distributors

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+ Raw material storage room is used for storing, checking and classification the quality

of raw materials, as well as preliminary processing before materials, go into processing

Processing area

The processing area plays an important role in the company in which raw materials (tea leaves) are directly variable into the final product (instant tea powder) Therefore, the area must be of high quality in order to obtain safe and high-quality products according

to GMP and HACCP standards

Packaging area

Applying proper packaging methods and ensuring hygienic conditions will reduce the risk of contamination with hazards in the packaging process to a minimum After packaging, the products are checked once again to ensure there is no mistake on the outlook and no metal contamination in each product

Packaging warehouse

Packaging warehouse is used to store packing materials to avoid cross-contamination and to expand space for the packaging process

Finished products warehouse

Finished product warehouse is where the products are stored as well as get ready for export

II Non-production area

Lab

It is used for microbiological testing in tea powder and other related matters, followed

by the administration

Freezing system

This system helps to control and maintain the ideal temperature for freezing steps

Water treatment system

The purpose of a water treatment facility is to make water potable and palatable while also ensuring that there is a sufficient supply of water for the company's water needs Raw water is pumped, or flows, to a treatment facility Once there, the water is pre-treated to remove debris such as leaves and silt Then, a sequence of treatment processes

- including filtration and disinfection with chemicals or physical processes - eliminates disease-causing microorganisms

9

Clean in Place system

In food processing, insufficient cleaning can result in reduced efficiency, contamination

in final product, and energy losses To optimize widely implemented clean-in-place

(CIP) systems, it is critical to understand the influence of the interactions between

surfaces, fouling, and chemical agents on the efficiency of the cleaning process

(Avila-Sierra, Zhang, & Fryer, 2019) This system helps to clean the interior surfaces of pipes,

vessels, types of equipment, filters without major disassembly

Waste storage

Proper waste management is important to protect human health and the environment,

so this area should be located in the farthest location to ensure hygiene and easily treat

the waste when it goes out of the environment

Employee canteen and relaxing area, packing area for employee's welfare and

visitor parking area for the welcome

PROCESS STEP DESCRIPTION

# Processing steps/ Incoming

After harvesting, it should be transported quickly to the processing factory

by trucks with specialized containers or by trucks carrying bags containing tea leaves Before being put into the warehouse, it must be carefully checked the quality assessment criteria

3 Water receiving Water is received from a water factory and stored in large water tanks

foil sachet

Aluminum foil sachets are delivered from the supplier and stored in the warehouse

5 Washing Leaves are washed to remove residue, sand on the surface of tea leaves The

water used to wash the tea leaves has a temperature of 25-30º C and drains

6 Rolling/Grinding

Firstly, the tea particles need to be made into small particles to increase the surface area contact of tea particles to the solvent to extract more soluble solid from the structure of the particles and not to impair the extraction yield Normally, the range of the particles size from around 100 micrometers to around 180 micrometers is optimal

7 Drying (Steaming)

Drying: High-temperature drying is not desirable for water-soluble components of green tea contain very easily oxidizable components, such as ascorbic acid and catechins Therefore, such drying methods as vacuum drying, freeze-drying, and spray drying are considered suitable

10

Steaming: The method comprises the following steps of pre-dissolving the tea raw materials such as tea leaves, tea stems, and tea residue, performing steam explosion under the pressure of 0.8 to 1.8MPa, keeping the pressure for 0.5 to 5 times, collecting the steam explosion material, and performing purification, concentration and drying according to the state of a steam explosion system to produce the instant green tea powder

8 Extraction

Using the hot extraction, the size of particles should be maintained larger, usually more than 500 micrometers to 800 micrometers The type of solvent used for this step should be low cost, safe for human health, safe for the environment So now people more refer to use water or ethanol However, ethanol is much more expensive compared to water So, people tend to use hot water with a temperature from 70oC to 90oC to increase the extraction yield of the soluble solid from the materials The ratio between the dry matters (tea particles) to the solvent should be in the range of 1:2 to 1:10 mean 1 portion in weight of the dry matters and 2 portions in weight of the solvent until 10 portions in weight of the solvent

9 Filtration At this step, the mixture of solid and liquid matters will be filtrated to remove extraneous objects or solid materials from the extraction step

dissolved in the solution This solution will be remixed with the input fluid before the freeze-drying step

11 Concentration

Using the osmotic evaporation (OE) process: The effect of the OE process on the content of phenolic compounds and antioxidant activity was evaluated The concentration process was carried out in a hollow fiber membrane contactor with an effective surface area of 0.54 m2 The tea extract was circulated through the shell side of the contactor, while a concentrated osmotic solution (CaCl2 5 M) was circulated inside the fibers It is possible

to reach a tea concentration of 40% (w/w) in 5h, with a constant water flux and without losing the phenolic content and antioxidant potential in most teas

12 Pre-Chilling

(Freezing)

During the freezing stage, the material is cooled below its triple point, the lowest temperature at which the solid, liquid,

and gas phases of the material can coexist

To facilitate faster and more efficient drying, larger ice crystals are preferable To produce larger crystals, the product should be frozen slowly

freeze-Temperature: -18OCTime: 2 hoursMethod: Using a cryogenic freezer upstream of a spiral freezer

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13 Freeze Drying

temperature dehydration process that involves freezing the product, lowering pressure, then removing the ice by sublimation.  Freeze drying is particularly useful for producing granules for instant tea and tea extracts The freeze-drying process allows the substances in the tea to retain their desired, useful properties, while, at the same time, the product remains highly soluble A freeze-dried tea dissolves extremely easily and quickly in water, but with that authentic taste of tea expected by the consumer

Freeze drying, also known as lyophilization or cryodesiccation, is a low-Temperature: -35oC Time: 8 hours Method: using a freeze dryer and a vacuum pump

14 Instant green tea

After placing the tea into the bag

Place the top of the between the seal bars

Press down gently for approximately 2-3 seconds and release

17 Metal detector

After packing and sealing, the product will be brought along the conveyor belt through the metal detector and if it detects that the metal fragment exceeds the allowable level, the machine will signal and stop the conveyor If

no metal fragments are detected, the product is removed from the metal detector by a conveyor belt

Metal detector testing frequency: 60 minutes / 1 time

18

Boxing/ Labeling

After packing, the product is placed on a tray that passes through the paper boxing system The product is put into a paper box, then it will go through a glue machine to glue the box

12

RISK ASSESSMENT AND CCP, OPRP DETERMINATION

# Processing Steps Identified Hazards

(B/C/P/A)

Hazard

Q1 Q2 Q3 Q4 Q5 CCP/OPRP

No

Subsequence step

1 Paper box receiving B: - - - HACCP - - - -

OPRP - - - -

C: - - - HACCP - - - -

OPRP - - - -

P: Dented, damaged paper box - Checking the quality of the receiving paper box carefully L L Mi HACCP ✓   - - -

OPRP ✓  - - - - -

A: - - - HACCP - - - -

OPRP - - - -

2 Tea leaves receiving B: Salmonella, E coli - Controlled by GMP/GHP H M Ma HACCP ✓  ✓ ✓ - 13 OPRP ✓  - - -

C: Chemical contamination can happen because of environmental pollution, inappropriate use of agrochemicals, sabotage, adulteration, residues of pesticides and pesticides - Controlled by GMP/ GAP H M Ma HACCP ✓   - - -

OPRP ✓ ✓ ✓ ✓  OPRP-1(C) - P: Sand, gravel - There is a stage to remove impurities in the material (sifter screen, clean the fresh tea place )

L H Mi HACCP ✓   - - 5

OPRP ✓  - - -

A: - - - HACCP - - - -

OPRP - - - -

3 Water receiving B: E Coli, Coliform - Check the quality of the water source in time -Controlled by GMP H M Ma HACCP ✓   - - -

OPRP ✓ ✓  - - - -

C: Pesticides, toxic substances - Controlled by GMP and SSOP H M Ma HACCP ✓   - - -

OPRP ✓ ✓ ✓  OPRP-2(C) P: Impurities Use a filter M M Ma HACCP ✓    - -

OPRP ✓ ✓  - - - -

A: - - - HACCP - - - -

OPRP - - - -

4 Aluminum foil sachet receiving B: - - - HACCP - - - -

OPRP - - - -

C: - - - HACCP - - - -

OPRP - - - -

P: Scraps of aluminum foil Check the quality and hygiene of the packaging according to GMP L L Mi HACCP ✓   - - -

OPRP ✓  - - -

A: - - - HACCP - - - - - -

OPRP - - - -

5 Washing B: Salmonella, E coli, Coliform Changing the water everyday batch of washing M M Ma HACCP ✓   - - -

13

OPRP ✓ ✓  - - - -

C: - - - HACCP - - - - - -

OPRP - - - -

P: Sand, dust, insect fragments Proper implementation of GMP Clean and maintain the machine regularly M H Ma HACCP ✓   - -

OPRP ✓ ✓ ✓  - OPRP-3(P) - A: - - - - - HACCP - - - -

OPRP - - - -

6 Rolling/Grinding B: - - - HACCP - - - -

OPRP - - - -

C: - - - HACCP - - - -

OPRP - - - -

P: Sand, dust Good implementation of GMP, SSOP Extraction will remove all impurities M M Ma HACCP ✓   - - - -

OPRP ✓  - - -

A: Tea dust (food allergy in sensitized individuals) Use N95, N99 Respirators or air filter masks H L Mi HACCP ✓   - - - -

OPRP ✓  - - -

7 Drying/Steaming B: Escherichia coli and Salmonella The organism’s heat sensitivity makes it possible to eliminate with LTHT treatment (low temperature and high temperature) H H Cr HACCP ✓   - - -

OPRP ✓  - - -

C: Chemical contamination can arise because of environmental pollution, lubricants from tea processing machinery, fumigant residues from the fumigation of containers To keep clean and, where necessary after cleaning, to disinfect, in an appropriate manner, facilities, equipment, containers Use the right amount of lubricant for machine maintenance M M Ma HACCP ✓   - - -

OPRP ✓  - - -

P: Iron particles To remove iron, magnets are often placed at the mouth of the dryer, belt, and color sorter to catch iron particles in different stages of the process M M Ma HACCP ✓   - - -

OPRP ✓  - - -

A: - - - HACCP - - - - - -

OPRP - - - -

8 Extraction B: Salmonella, E coli, Cryptosporidium parvum, Coliform Clean water testing, water treatment operation, water analysis before extracting L L Mi HACCP ✓   - - -

OPRP ✓  - - -

C: E pidallocatechin-3-gallate, chlorine Control the concentration of substances to the minimum allowed M L Mi HACCP ✓   - - -

OPRP ✓  - - -