ABC SEAFOOD IMPORT - EXPORT & PROCESSING JOINT STOCK COMPANY

HACCP COOKED PDTO ,PD SHRIMP



here are many different systems of quality management applied

in industrial production in the world nowadays They are, namely, GMP, HACCP, ISO 9000 and TQM Every system has its own distinctive features and approaches Seafood producers in the country as well as our ABC Company often face these questions: Which quality management system should be chosen for our business? Which

of those systems is suitable for the quality of our product in our specific economic conditions? Which of them can really suit us to meet customers’ demand for qualified, hygienic and wholesome products and hence win their acceptance and credence ?

a decisive matter and must be strictly realized from the first step of material collecting to the finished products to ensure their best quality.

Customers are now demanding quality instead of quantity of products As for foodstuff, quality is crucial not only to determine whether a product could find its feet in the market but also to expose the responsibility of a conscientious producer to the society.

Anyway, to solve the quality problem, it demands much effort in renewing the way of our economic thinking as well as in improving mechanism of our management In addition, investment in modern equipment and instruments for production should be further enforced.

Since having acquired necessary conditions, our ABC Company has drastically applied the GMP system in our production activities The approaches have brought us remarkable initial results.

However, we wish to go further in making our products better and more competitive We have decided to seek helps from The Ministry of Fisheries The Ministry then helped us, and other businesspersons who had registered to export their products to EU & USA markets, to put the HACCP into effect in our processing activities.

producing FROZEN IQF COOKED SHRIMP PRODUCTS – PDTO, PD.

ABC.

ABC COMPANY THE SOCIALIST REPUBLIC OF VIETNAM

***** Independence - Freedom -Happiness -***** -

Ref NO:07/QDCTY/2009 ABC, Jan 01 st , 2009

DECISION OF DIRECTOR OF ABC

( MODIFICATION ON TEAM OF HACCP BASED PROGRAM FOR QUALITY MANAGEMENT FOR FROZEN IQFCOOKED SHRIMPS PRODUCTS – PDTO, PD)

- In reference to Decision No: 105/QD/UB dated on 28th September, 1992 issued by Minh Hai Province People's Committee on the establishment of the company.

- Based on the business license No: dated on 09th October, 1992 and ratified

by Minh Hai Province economic Arbitrator.

- Based on Decision No: 02/QDCTY.97 dated on 30th November, 1997 issued by Director of Company.

- According to the directions of the Ministry of Fisheries & NAFIQAVED for all enterprises in need of exporting to seafood to U.S.A & EU markets.

- Considering the proposals of QC Chief.

DECIDES Articles 1 : Modification on the Team of HACCP-based program for quality management for Frozen IQF Cooked shimps products – PDTO, PD.

Article 2: All concerned divisions and the members in the HACCP Team have

responsibilities for developing and implementing the regulations as mentioned in

"responsibilities, functions, duties and rights of HACCP Team".

Article 3: All concerned divisions and the members as mentioned in the list must

carry out this decision.

This decision is validated from the signing date

- HACCP Team

- All production groups

- Kept by Administrative Dept., HACCP records

ABC COMPANY THE SOCIALIST REPUBLIC OF VIETNAM

***** Independence - Freedom -Happiness

Ref NO:08/ QDCTY/2009 ABC, Jan 01 st , 2009

DECISION OF DIRECTOR OF ABC

( PROMULGATION ON HACCP BASED PROGRAM FOR QUALITY MANAGEMENT

FOR FROZEN IQF COOKED SHRIMPS PRODUCTS – PDTO, PD)

- In reference to Decision No: 105/QD/UB dated on 28th September, 1992 issued

by Minh Hai Province People's Committee on the establishment of the company.

- Based on the business license No: dated on 09th October, 1992 and ratified

by Province Minh Hai economic Arbitrator.

- Based on Decision No: 02/QDCTY.97 dated on 30th November, 1997 issued by Director of Company.

- According to the directions of the Ministry of Fisheries & NAFIQAVED for all enterprises in need of exporting to seafood to U.S.A & EU markets.

- Considering the proposals of QC Chief.

DECIDES

Article 1 : This decision is promulgated together with HACCP-based program for quality management for Frozen IQF Cooked shrimps products - PDTO, PD.

Article 2: The HACCP team is responsible for developing and implementing

production reality on approved program.

Article 3: The HACCP team should hold monthly meeting and record on writing

the implementation program, and give comments for modification.

Article 4: The HACCP team and concerned divisions have responsibilities for

implementing this decision.

This decision is validated from the signing date

- All production groups

- Kept by Administrative Dept., HACCP records

HACCP-2009

4

N O MEMBERS Professional Levels Positions Responsibilities

- Selecting and developing HACCP plan

- Verifying the HACCP implementation plan and submitting to Director for approval

- Co-ordination relative activities to support HACCP team

* Responsible for HACCP implementation

- Setting up and adjusting quality managementprograms: HACCP, GMP, SSOP

- Training workers

Responsible for implementation of quality management program

- Making operation plans for HACCP team

3 TRAN THANH BINH

(Member)

Intermediate Technician Chief of technical

department

Responsible for maintenance and upgrading

of processing conditions (equipment, instrument and workshop)

4 NGUYEN THI MAI

- Collecting reports to Director Boarding

- Responsible for controlling raw material quality

7 PHAM THI RA

(Member)

Bachelor of administration business

Deputy production manager

Responsible generally for workshop

8 NGUYEN TRONG PHAN

(Member)

Engineer of food processing Chief of QC Quality control of product

HACCP - 2009

5

HACCP - 2009

- IQF Conveyor belt

- Cooking and chilling

HASEGAWA (JAPAN)HASEGAWA (JAPAN)HASEGAWA (JAPAN)

HASEGAWA (JAPAN)HASEGAWA (JAPAN)DenmarkJAPAN

JAPANJAPAN

400KGS/hour

700 KGS/hour

640 KGS/Batch

960 KGS/Batch

320 KGS/Batch

320 KGS/Batch

500 KGS/Batch

100 tones/Store

75 tones/Store

020101

01010101

010201010101

11

2001200119881983198819901997

19881988

1988199719972001

19881990ForeignForeignForeignForeign

2h50'3h50'2h50'2h50'2h50'

-18oC ¸

-25oC -18oC ¸ -

25oC +5oC ¸ -5oC

HACCP - 2009

9

JAPANTAIWANJAPAN

3102

2001

1997-ORGANISATIONAL FLOW CHART FOR QUALITY MANAGEMENT

Management

HACCP Team

Technology and Product Outlook

Micro-biological Test

Ice Flakes

Production

Water Treatment

Ice Block Production Collecting Spot

Raw Material Receiving

Agent

Sanitary Team

Receiving Team

Primary Processing

Processing

Quick Freezing

Packing

Packaging Material Store

Chemical Store

Material Preserving Store

Product Storage

PROCESS FLOW CHART

RAW MATERIAL RECEIVING CCP1: -Antibiotic.

Date of verification : 01/01/2009

PRODUCT DESCRIPTION

-a a a

-NAME OF PRODUCTS: FROZEN IQF COOKED SHRIMP PRODUCTS – PDTO, PD

1 Product name Frozen IQF Cooked shrimps products – PDTO, PD

2 Scientific name of raw

- Bag: 2LBs x 10bags/master carton

6 Other ingredient(s) Salt and Phosphate blend (Preservative), its trade mark is Brifisol

512 new – Made in Germany

8 Packaging types IQF: 2lbs per poly-bag – from 5 to 10 poly-bags in master carton

Sealed bags with vaccum or without vaccum, and net weight orgross weight depends on customer,s specification

9 Storage condition In the cold store, the finished products are stored with TO £ - 20OC +

11 Shell life 24 months from production date

12 Best before sale

13 Label requirements On the label the following information must be written such as

product name, size, net weight, production date, expiration date,producer name, logo and address of producer

14 Special conditions None

HACCP - 2009

15

15 Intended use Ready-to-eat Products

16 Intended consumer General population

17 Applicable regulations Vietnamese standards or the customer,s standards or orther

importer,s requirements However, it must not be lower thanVietnamese standards

steps Main specifications Brief description

- Fresh prawns, free of After being caught, fresh prawns are well

transportation means, preserving conditions and such quality requirements as the

freshness, the ordour, and strange matters in the material.

01ST Wash

Washing water TO < 5OC Prior to processing the raw materials must be

washed for removing all objectionable matters

in chlorine water (chlorine concentration: 50 ppm)

Raw

Material Kept

Refrigerated

- The proportion of prawn to ice: 1:1

- Temperature in storage: 0-4oC.

- Temperature of prawn bodies must be kept under 4oC.

- To follow with each size.

- Heads are removed from the prawns The process is quickly finished to prevent micro- organisms from developing.

- This step will not be taken if prawns are to be process whole.

- QCs observe the temperature with their hand thermometer.

- Checking sizes and processing preliminarily: Using scissors and knife to trim shrimp.

- Each shrimp basket is washed through 02 clean water times in 02 water basins.

Sizing/

Grading

- Classifying prawns in sizes or types on customers, taste or on Vietnam quality

- Classifyed prawns are quickly taken to the next step.

03rd washed

- Washing 1-2kg / basket each time.

- Each shrimp basket is washed through 03 clean water times in 03 water basins.

Soaking by

STPP blend

& Salt

- Max concentration of STPP Blend: 2%

- Salt cocentration: 2%

- Soaking time: 60 minutes

- Soaked by phosphate blend or not (basing

on the customer s requirements) ’s requirements).

- Preservative is diluted into water according

to the directions And shrimp is soaked into water with the rate 1:1.

- Note: Preservative is put into water first and

HACCP - 2009

17

then salt

04th Washed

- Washing 1-2kg / basket each time.

- Each shrimp basket is washed through 03 clean water times in 03 water basins.

Check

foreign

matter

No foreign matter in products Check foreign matter by checking special tables (with white board by 3 persons step by

- Chilling temperature should be lower 5oC.

Cooling on the conveyer with maximum of 5 minutes and not controlled with the circulation running water flow

Chilling in tank with cold running water.

Freezing

On IQF conveyor with max time: 30 minutes, central temperature of product: attained -18oC

Shrimps are put on the conveyor system and the speed of conveyer is adjusted

appropriately.

Glazing

- Water glazing temperature should be lower than 5oC.

- Sanitizing concentration according

to guidelines of food processing line.

Use automatic water spraying equipment system for glazing.

Re- freezing On IQF conveyor with maximum 15 minutes,

central temperature of product: attained -18oC

Use automatic re-freezer o freeze products again after glazing

Weighing

And packing

- Net WT + 2% collateral weight.

- IQF: 2lbs per poly-bag

10 poly-bags in master carton.

- Use electrical scale for weighing.

- Basing on the customer,s specifications and guidelines of food processing line.

- Remarking “Farm Raised” if export to America market.

Metal

detecting

- No metal allowed in the product - Metal detecting by automatic machines Checking the machine by standard samples or

parallel sample.

Cold Storage

- Temperature of cold store: - 20oC ± 2

refrigeration trucks: -

20oC ± 2

- Not to use preserver with raw products or in container and

refrigeration trucks.

- To abidde technical requirements.

Date of verification : 01/01/2009

(Signature)

HAZARD ANALYSIS WORKSHEET

* PRODUCT NAME: FROZEN IQF COOKED SRHIMP PRODUCTS – PDTO, PD

Ingredient/

Processing step

Identify potential hazards introduced, controlled or enhanced

at this step (1)

Are any Potential Food-safety Hazards Significant?

(Yes/No)

Justify your decisions for column 3

What preventive measures can be applied to prevent the significant hazards ?

Is this step a critical control point ? (Yes/No)

bacteria is inherent

in the raw material from acquaculture and harvesting areas and during

- Pathogenic bacteria

is limited at cookingstep

No

HACCP - 2009

19

MATERIAL storage and

transportation to the factory

Chemical:

- Residue of toxicsubtances in environment ( Pesticide &

heavy metal)

- Residuee of veterinary drugs

- Sulfite-Cloramphenicol

-Nitrofuran

Yes

Yes

YesYes

Yes

- It is present in aquaculture areas

- It is present in feeds and in drug treating prawns

- It is present in feeds and in drug treating prawns

- It is present in feeds and in drug treating prawns

- It is present in feeds and in drug treating prawns

Raw material is onlybought from thecontrolled aquaculture

or unforbibden areas

or the areas are

substances by officalmanagernent

NAFIQACEN

- Only receive lost ofraw material whichstops using antibiotic

in 04 weeks from thecommitment of rawmaterial suppliers

- Test sulfite by testpaper

- Monthly take sample

chloramphenicol inenvironment

-6 Months takesample for testing of

and in drug treating prawns

Taking sample for

- Bacterial contamination

No

No

- Pathogenic micro growth is not likely

to occur because of short time of wash and it is controlled

by GMP

- Controlled by SSOP

- Bacterial contamination

NoNo

- Controlled by GMP

- Controlled by SSOP

- Bacterial contamination

NoNo

- Controlled by GMP

- Controlled by SSOP

- Bacterial contamination

No

No

- Pathogenic micro growth is not likely

to occur because of short time of wash and it is controlled

by GMP

- Controlled by SSOP

- Bacterial contamination

NoNo

- Controlled by GMP

- Controlled by SSOP

- Bacterial contamination

No

No

- Pathogenic micro growth is not likely

to occur because of short time of wash and it is controlled

by GMP

- Controlled by SSOP

- Bacterial contamination

NoNo

- Controlled by GMP

- Controlled by SSOP

Chemical:

Residue of

concentration of preservetive for use has never been exceeded the acceptable level

- Bacterial contamination

No

No

- Pathogenic micro growth is not likely

to occur because of short time of wash and it is controlled

by GMP

- Controlled by SSOP

Chemical:

None

Physical:

None

TRAY LAYING

Biological:

- Pathogenic micro growth

- Bacterial contamination

No

No

- Pathogenic micro growth is not likely

to occur because it

is controlled by GMPand short time of performance

- Controlled by SSOP

- Pathogenous bacterial survival after steaming

Yes

No

- Without proper processing time and temperature, bacterial pathogens such as Listeria Monocytogenes, Salmonella ssp, andVibrio ssp, may survive

- Because of proper steaming, controlled

by SSOP

Adequate cooking time and temperature

Yes

Chemical:

Sanitizer residues

- Bacterial contamination

No

No

- Pathogenic micro growth is not likely

to occur because it

is controlled by GMPand short time of performance

- Controlled by SSOP