HACCP implementation in the production of tomato products

Abstract

This dissertation describes the preliminary work done by the author to set up an HACCP system at Vernon's Foods, Industrial Estate, Mriehel in the processing of Polpa, Passata and Pelati tomato products. The methodology used followed the guidelines for the setting up of HACCP systems published by FAO. Professor V. Ferrito, the tutor Dr. A. Mcelhatton, Mr. H. Micallef, the author and the Quality Control Manager of the plant, Mr. D. Borg were the members of the HACCP team. The products and their intended use are described. A11 audit of the goods received system was carried out to determine the possible hazards that could be introduced from the raw materials. In direct consultation with the operators a schematic diagram of the plant and the flow diagrams for the production of different tomato products were prepared. These were verified by several 'walk through' audits following the process steps one by one and discussing any relevant issues with the Quality Control Manager. Since the implementation of HACCP can only be effective if the plant has in place all the necessary pre-requisites illustrated in this dissertation, the author made several recommendations. These recommendations were discussed and explained to the Quality control Manager. Basing on published reports, books, relevant research documents and in-house experiences the physical, chemical and biological hazards, if any, associated with each process step were identified. For each hazard identified and associated with a particular process step, the process step was classified as either a Critical Control Point or a Control Point by making use of the recommended Decision Tree approach. Following the identification of the control points, monitoring and frequency of monitoring, critical limits and 'corrective actions' to be taken and by whom in case of deviations, were established. Since the keeping of records is an essential requisite for the setting up of the HACCP system as well as for its subsequent and regular verification and validation, all relevant documentation was prepared. An excel spreadsheet for the calculation of Pasteurisation Units (PU's) was also prepared. In conclusion a strong case and an equally strong recommendation is made for the Management of the plant to introduce, implement, and maintain the HACCP system designed in this dissertation which is now a mandatory legal requirement.