Benefits of retort pouch:
1. A pouch takes less time to reach sterilization temperature than can or jar, which is due to the thinner pouch profile and its larger surface area per unit volume. In addition, because the product near the surface is not overcooked, as it can be with cans and jars, the [product quality is better maintained. The product retains its color, remains firmer in texture and fresher in flavor, and experiences less nutrients loss. The pouch is especially beneficial for such products as delicate sauces, seafood, and entrees, where color and texture are important. Also, products such as vegetables can be packed in retort pouches with less brine (required for improving the heat transfer processes). Thus, there is less shipping weight and less discarding of brine.
2. A pouch product is commercially sterile, does not require refrigeration or freezing, and its shelf-stable at room temperature.
3. Pouched food can be eaten without heating, or it can be heated quickly by placing the pouch in boiling water for a few minutes. Frozen foods, in contrast, require heating for about half an hour. Thus, less energy is required for heating a retort pouch. Pouched food can also be heated in a microwave oven simply by removing it from the pouch before heating.
4. A pouch can be easily and safely opened by tearing it across the top at the notch in the side seal or by cutting it with scissors. There is no need for a can opener and no danger from can lids or broken glass. There is also no problem in handling a pouch immediately after removal from boiling water.
5. There is no need to get pots or pans—or even dished—messy. The food can be eaten directly from a pouch or served on dishes.
6. Pouches weight less than comparable cans and jars, thus reducing distribution costs.
7. Pouches, empty and full, take up less storage space than comparable cans, jars and trays. Empty pouches, for example, occupy up to 85%less storage space and cans.
8. Pouches, including paperboard cartons, will most likely require less energy to manufacture than cans, jars, and trays. In addition, studies indicate that the total energy required from harvesting to consumption is about 60% lower than for canned vegetables.
9. The combination of shelf stability without refrigeration and the light weight of a pouch make retort-pouched product idea for military use as well as for recreational camping.
10. The capability of serving single portion of foods makes the retort pouch desirable for the single market and the hospital-feeding market.
11. The ease of preparation and opening, as well as the elimination of the need for such storage space and refrigeration, makes the retort pouch desirable for use in the feeding of elderly.
12. The ability to package large quantities of foods in less bring makes the retort pouch desirable for use in institutional feeding.
Friday, April 20, 2007
Thursday, April 19, 2007
curry chicken recipe(new)
Chicken Curry Pasta
Ingredients:
4 kg Vegetable oil
5 kg Fresh shallot, minced
0.8 kg Fresh garlic, minced
0.6 kg Fresh young ginger, minced
0.3 kg Fresh galangal, minced
4 kg Dried chilli paste
0.8 kg Dried candlenut, minced
0.7 kg Curry powder
10 g Cinnamon powder
10 g Clove powder
10 g Cardamom powder
5 g Star anise powder
19 g Kaffir lime leaf powder
0.6 kg Salt
1.4 kg Sugar
3.8 kg Tomato paste
40 g Citric acid
4.0 kg Evaporated milk
1.7 kg Lemongrass water
18 kg Water
250 g Colflo 67(thickener)
22 kg Chicken leg cube, boneless, blanched
5 kg Green pea, thawed and washed
17.5 kg Twisted pasta
Materials:
350 Pouches
Process flow chart:
1.Vegetable oil
2.Fresh shallot, minced
3.Fresh garlic, minced 1-7
4.Fresh young ginger, minced Weighing Pour into Pour into steam kettle. Turn on steam,
5.Fresh galangal, minced steam kettle heat to 80-90˚C
6.Dried chilli paste
7.Dried candlenut, minced Stir fry until fragrant while maintain
8.Curry powder temperature at 80-90˚C
9.Cinnamon powder 8-12
10.Clove powder Stir fry until oil separates while
11.Cardamom powder maintain temperature at 80-90˚C
12.Star anise powder 13-20
13.Kaffir lime leaf powder Rinse side of kettle with part of
14.Salt water and mix until homogeneous
15.Sugar 21
16.Tomato paste Wash Colflo67 solution with
17.Citric acid remaining water. Mix until
18.Evaporated milk homogeneous. Heat up to70+/-3˚C
19.Lemongrass water and maintain at this temperature.
20.Water
21.Colflo67 Liquid is piped to filling line(ccp1)
22.Chicken leg cubes, boneless, blanched
23.Green pea, thawed&washed Filled into the pouches
24.Twisted pasta, raw
Filling the liquid into the pouches,
Labeling and sealing.(ccp2)
Cooking sterilizing cooling
In the retort(ccp3)
Drying and packaging
Ingredients:
4 kg Vegetable oil
5 kg Fresh shallot, minced
0.8 kg Fresh garlic, minced
0.6 kg Fresh young ginger, minced
0.3 kg Fresh galangal, minced
4 kg Dried chilli paste
0.8 kg Dried candlenut, minced
0.7 kg Curry powder
10 g Cinnamon powder
10 g Clove powder
10 g Cardamom powder
5 g Star anise powder
19 g Kaffir lime leaf powder
0.6 kg Salt
1.4 kg Sugar
3.8 kg Tomato paste
40 g Citric acid
4.0 kg Evaporated milk
1.7 kg Lemongrass water
18 kg Water
250 g Colflo 67(thickener)
22 kg Chicken leg cube, boneless, blanched
5 kg Green pea, thawed and washed
17.5 kg Twisted pasta
Materials:
350 Pouches
Process flow chart:
1.Vegetable oil
2.Fresh shallot, minced
3.Fresh garlic, minced 1-7
4.Fresh young ginger, minced Weighing Pour into Pour into steam kettle. Turn on steam,
5.Fresh galangal, minced steam kettle heat to 80-90˚C
6.Dried chilli paste
7.Dried candlenut, minced Stir fry until fragrant while maintain
8.Curry powder temperature at 80-90˚C
9.Cinnamon powder 8-12
10.Clove powder Stir fry until oil separates while
11.Cardamom powder maintain temperature at 80-90˚C
12.Star anise powder 13-20
13.Kaffir lime leaf powder Rinse side of kettle with part of
14.Salt water and mix until homogeneous
15.Sugar 21
16.Tomato paste Wash Colflo67 solution with
17.Citric acid remaining water. Mix until
18.Evaporated milk homogeneous. Heat up to70+/-3˚C
19.Lemongrass water and maintain at this temperature.
20.Water
21.Colflo67 Liquid is piped to filling line(ccp1)
22.Chicken leg cubes, boneless, blanched
23.Green pea, thawed&washed Filled into the pouches
24.Twisted pasta, raw
Filling the liquid into the pouches,
Labeling and sealing.(ccp2)
Cooking sterilizing cooling
In the retort(ccp3)
Drying and packaging
Monday, April 16, 2007
singapore food industries ltd
Company Overview
Since its incorporation in 1973, Singapore Food Industries (SFI) has grown to be a leading integrated food company in Singapore, drawing synergies from its various businesses. The Group is focused on meeting changing food needs driven by changes in lifestyle and demographic patterns. Besides Singapore, we have established a significant presence in United Kingdom, and made forays into the Republic of Ireland, China and Australia as the footholds for future development into the promising European and Asia-Pacific markets.
In FY2005, SFI achieved profit after tax of $36.1 million on turnover of $597.1 million. Its overseas subsidiaries contributed 59% to Group turnover.
Our three core businesses are Food Distribution, Food Preparation, Manufacturing, & Processing and Abattoir & Hog Auction.
In Singapore, the group has well-developed facilities and extensive distribution network: Over 35,000 sq. metres of warehouse, cold storage, production and other facilities; A large fleet of over 100 refrigerated trucks; Two large-capacity kitchens (one of which is halal certified) fitted with advanced equipment capable of producing 60,000 meals a day; HACCP certified Retort Production line; State of the art Product Development Centre and QC laboratory to ensure stringent quality standards; Modern abattoir and auction facilities.
SFI is dedicated to 'delighting the customer' as its goal. The Company's responsiveness to customers' requirements is its trademark and competitive edge.
It takes pride in continuous staff training at all levels, many of whom have extensive experience and expertise across a wide cross-section of skills from Food Technology and Microbiology, to the field of Logistics.
Since its incorporation in 1973, Singapore Food Industries (SFI) has grown to be a leading integrated food company in Singapore, drawing synergies from its various businesses. The Group is focused on meeting changing food needs driven by changes in lifestyle and demographic patterns. Besides Singapore, we have established a significant presence in United Kingdom, and made forays into the Republic of Ireland, China and Australia as the footholds for future development into the promising European and Asia-Pacific markets.
In FY2005, SFI achieved profit after tax of $36.1 million on turnover of $597.1 million. Its overseas subsidiaries contributed 59% to Group turnover.
Our three core businesses are Food Distribution, Food Preparation, Manufacturing, & Processing and Abattoir & Hog Auction.
In Singapore, the group has well-developed facilities and extensive distribution network: Over 35,000 sq. metres of warehouse, cold storage, production and other facilities; A large fleet of over 100 refrigerated trucks; Two large-capacity kitchens (one of which is halal certified) fitted with advanced equipment capable of producing 60,000 meals a day; HACCP certified Retort Production line; State of the art Product Development Centre and QC laboratory to ensure stringent quality standards; Modern abattoir and auction facilities.
SFI is dedicated to 'delighting the customer' as its goal. The Company's responsiveness to customers' requirements is its trademark and competitive edge.
It takes pride in continuous staff training at all levels, many of whom have extensive experience and expertise across a wide cross-section of skills from Food Technology and Microbiology, to the field of Logistics.
Saturday, April 14, 2007
critical control points & recall plan
NO.
Critical limit
Monitoring procedures
Corrective actions
CCP1
Metal detection
(solid filling)
1.No ferrous metal³1.2mmǿ
2.No non-ferrous metal³2.0mmǿ
What
Detect metal in plastic cups filled with solid items.
--When metal objects are detected, the “channeliser” will segregate the affected cup
--This will activate the alarm and the executive will be notified.
--The foreign matter will be removed and an investigation has been conducted by the team to identify the source of contamination.
--Production will only be resumed after approval of executive or manager in charge.
How
Metal detector
When
At the end of manual filling process.
Where
On the conveyer belt leading to filling machine.
Who
1.Operator to take note of any alarm from detector.
2.Executive or supervisor to record any detected metal pieces.
((Liquid filling)
What
Detect metal in gravies passing through piping to filling machines.
--This will activate the alarm and the executive will be notified.
--The foreign matter will be removed and an investigation has been conducted by the team to identify the source of contamination.
--Production will only be resumed after approval of executive or manager in charge.
How
Metal detector
When
During the pumping of the gravies to the filling machines.
Where
At the start of the pipes leading from kettle to the filling machines’ hopper.
Who
1.Operator to take note of any alarm from detector.
2.Executive or supervisor to record any detected metal pieces.
CCP2
Sealing
Of pouches
175-180˚C
Specific control measure: no commence of sealing process is allowed when the required temperature is not reached.
What
Check the temperature settings are correct
--If any required temperature cannot be achieved/maintained during equipment malfunction.
1.Do not start the process.
2.Inform Maintenance Team immediately to rectify and service the equipment.
If the fault cannot be remedied due to major breakdown and ect:
1.Maitenance will arrange for external professional engineer to repair.
2.The machine will be stopped until further instruction from manager.
3.The activity at this machine will be transferred to another line.
How
Check the digital reading of the thermometer.
When
Before the start of production and every 2hours during production.
Who
Supervisor
CCP3
Sterilization/
Retorting
121˚C for 45 minutes
at 0.188-0.212mPa
What
Check the correct sterilization parameter.
--If the sterilization setting incorrect due to wrong pattern card being used:
1.Before start of sterilization, change to correct card immediately.
2.After start of/during process: report to Production Executive immediately.
-Production executive will use the engineering card to overwrite and correct the setting to the required parameters.
3.If sterilization process already completed and the parameters used is higher than the required specification,
-Quarantined the product for sensory evaluation and decision by manager.
4.If the sterilization process already completed and the parameter used is lower than the required specification,
-Quarantined the product for microbiological testing and decision by manager.
How
Check the parameter shown on the control panel screen.
When
Before the start of each sterilization cycle
Where
At the control panel of the retort sterilizer.
Who
Retort operator or Production executive.
Recall procedures:
A product recall can be voluntary in the event that company detects the defect through its QA and HACCP Plan or involuntary if the Authority (NEA or AVA) or the customers detect the problem.
A recall can be categorized into the following 3 categories:
Class І: The product will be probably cause serious public health hazards, perhaps even death e.g. Contamination with pathogenic bacteria or toxic materials.
Class П: The product may cause health hazards, but is unlikely to lead to serious injuries or illnesses, e.g. Contamination with microorganism and product spoilage.
Class Ш: The product will not cause a public health hazards, e.g. Non-critical labeling errors.
In a event of a Class І product recall, the senior management will activate the necessary arrangement to recall the product immediately.
In the event of a Class П product recall, the senior management will be informed and the business director or the Food preparation manager will initiate the product recall.
In the event of Class Ш product recall, the business director or the Food preparation manager will be informed and the QA manager will initiate the product recall.
If the in-house monitoring program detects unsafe product from the plant, the QA manager will activate key members of Quality Planning Team to collect, analyze and evaluate all information related to the product.
Upon confirmation that the particular production lot falls into Class І or Class П, the QA Manager will report to the senior management and obtain approval to recall the affected products.
The QA manager will then call for a meeting, chaired by Food preparation manager to activate the recall program. The Operation manager, Warehouse manager, Export manager, catering manager and the Corporate Communication Manager will be provided with details of the affected production lot.
The warehouse manager will be responsible for quarantining all existing stock of the affected products in the warehouse while the Sales manager will coordinate with the customers to recall the affected products from the customers. Warehouse manager will also be responsible for the retrieval of affected products from customers.
If the products involves overseas sale, the Export manager will liaise with the oversea distributor/agents and advise them to arrange for a product recall. Once the products have been recalled to the distribution center, the overseas distributor may then inform the company and the Export manager will lead a QA team to conduct a thorough investigation on the recalled product.
Packaging condition: thick army green pouches 200g—300g
Product shelf life: 1—2years
Microbial specifications:
Sterilized product: --No brown pouches for commercial sterility test
--“Negative” results for TPC tests
Pasteurized product: --<10ˆ5 cfu/g TPC
--<10ˆ2 cfu/g Yeast Plate Count test
--<10ˆ2 cfu/g Mould Plate Count
Chiller: 4.0—4.5˚C
Freezer:-15.0-- -18.0 ˚C
Retort: 121˚C--125˚C for 45 minutes
Pressure:0.188mPa—0.212mPa
Critical limit
Monitoring procedures
Corrective actions
CCP1
Metal detection
(solid filling)
1.No ferrous metal³1.2mmǿ
2.No non-ferrous metal³2.0mmǿ
What
Detect metal in plastic cups filled with solid items.
--When metal objects are detected, the “channeliser” will segregate the affected cup
--This will activate the alarm and the executive will be notified.
--The foreign matter will be removed and an investigation has been conducted by the team to identify the source of contamination.
--Production will only be resumed after approval of executive or manager in charge.
How
Metal detector
When
At the end of manual filling process.
Where
On the conveyer belt leading to filling machine.
Who
1.Operator to take note of any alarm from detector.
2.Executive or supervisor to record any detected metal pieces.
((Liquid filling)
What
Detect metal in gravies passing through piping to filling machines.
--This will activate the alarm and the executive will be notified.
--The foreign matter will be removed and an investigation has been conducted by the team to identify the source of contamination.
--Production will only be resumed after approval of executive or manager in charge.
How
Metal detector
When
During the pumping of the gravies to the filling machines.
Where
At the start of the pipes leading from kettle to the filling machines’ hopper.
Who
1.Operator to take note of any alarm from detector.
2.Executive or supervisor to record any detected metal pieces.
CCP2
Sealing
Of pouches
175-180˚C
Specific control measure: no commence of sealing process is allowed when the required temperature is not reached.
What
Check the temperature settings are correct
--If any required temperature cannot be achieved/maintained during equipment malfunction.
1.Do not start the process.
2.Inform Maintenance Team immediately to rectify and service the equipment.
If the fault cannot be remedied due to major breakdown and ect:
1.Maitenance will arrange for external professional engineer to repair.
2.The machine will be stopped until further instruction from manager.
3.The activity at this machine will be transferred to another line.
How
Check the digital reading of the thermometer.
When
Before the start of production and every 2hours during production.
Who
Supervisor
CCP3
Sterilization/
Retorting
121˚C for 45 minutes
at 0.188-0.212mPa
What
Check the correct sterilization parameter.
--If the sterilization setting incorrect due to wrong pattern card being used:
1.Before start of sterilization, change to correct card immediately.
2.After start of/during process: report to Production Executive immediately.
-Production executive will use the engineering card to overwrite and correct the setting to the required parameters.
3.If sterilization process already completed and the parameters used is higher than the required specification,
-Quarantined the product for sensory evaluation and decision by manager.
4.If the sterilization process already completed and the parameter used is lower than the required specification,
-Quarantined the product for microbiological testing and decision by manager.
How
Check the parameter shown on the control panel screen.
When
Before the start of each sterilization cycle
Where
At the control panel of the retort sterilizer.
Who
Retort operator or Production executive.
Recall procedures:
A product recall can be voluntary in the event that company detects the defect through its QA and HACCP Plan or involuntary if the Authority (NEA or AVA) or the customers detect the problem.
A recall can be categorized into the following 3 categories:
Class І: The product will be probably cause serious public health hazards, perhaps even death e.g. Contamination with pathogenic bacteria or toxic materials.
Class П: The product may cause health hazards, but is unlikely to lead to serious injuries or illnesses, e.g. Contamination with microorganism and product spoilage.
Class Ш: The product will not cause a public health hazards, e.g. Non-critical labeling errors.
In a event of a Class І product recall, the senior management will activate the necessary arrangement to recall the product immediately.
In the event of a Class П product recall, the senior management will be informed and the business director or the Food preparation manager will initiate the product recall.
In the event of Class Ш product recall, the business director or the Food preparation manager will be informed and the QA manager will initiate the product recall.
If the in-house monitoring program detects unsafe product from the plant, the QA manager will activate key members of Quality Planning Team to collect, analyze and evaluate all information related to the product.
Upon confirmation that the particular production lot falls into Class І or Class П, the QA Manager will report to the senior management and obtain approval to recall the affected products.
The QA manager will then call for a meeting, chaired by Food preparation manager to activate the recall program. The Operation manager, Warehouse manager, Export manager, catering manager and the Corporate Communication Manager will be provided with details of the affected production lot.
The warehouse manager will be responsible for quarantining all existing stock of the affected products in the warehouse while the Sales manager will coordinate with the customers to recall the affected products from the customers. Warehouse manager will also be responsible for the retrieval of affected products from customers.
If the products involves overseas sale, the Export manager will liaise with the oversea distributor/agents and advise them to arrange for a product recall. Once the products have been recalled to the distribution center, the overseas distributor may then inform the company and the Export manager will lead a QA team to conduct a thorough investigation on the recalled product.
Packaging condition: thick army green pouches 200g—300g
Product shelf life: 1—2years
Microbial specifications:
Sterilized product: --No brown pouches for commercial sterility test
--“Negative” results for TPC tests
Pasteurized product: --<10ˆ5 cfu/g TPC
--<10ˆ2 cfu/g Yeast Plate Count test
--<10ˆ2 cfu/g Mould Plate Count
Chiller: 4.0—4.5˚C
Freezer:-15.0-- -18.0 ˚C
Retort: 121˚C--125˚C for 45 minutes
Pressure:0.188mPa—0.212mPa
Monday, April 9, 2007
retort pouch
The retort pouch is a flexible laminated food package that can withstand thermal processing. It has the advantage of offering the shelf stability of metal cans, coupled with the texture and nutrient value associated with frozen foods. The retort pouch has been considered the most significant advance in food packaging since the metal can, and has the potential to become a feasible alternative to the metal can and glass jar.16
The U.S. Army promoted the concept of flexible retortable pouches for use in combat rations in the 1950's. The idea was to have a lightweight, easy-to-pack, shelf-stable food container in order to eliminate the heavier traditional can. Research continued through the 1960's. In 1965 the first commercial retort pouches were produced in Italy. In Japan, retort pouch technology has been widely accepted16 and there are many varied products on the shelf, ranging from sukiyaki to soup.
The retort pouch has a number of advantages compared to a metal can.
The thin profile permits a reduced heating time and thus less of a chance to overcook the product while producing better color, firmer texture and less nutrient loss. The manufacturer has reduced energy requirements for pouch production as compared to that for metal cans.14 The pouch (because of its thinner profile) transfers heat faster to its critical point. During processing, this permits the required amount of heat for proper sterilisation to reach the critical point with minimal overcooking of the product near the peripheral container areas. Thus, for those food commodities subject to quality loss from excessive heating during the process cycle, the flexible container offers the benefit of higher quality together with better retention of the heat-sensitive nutrients.
The thermal process is complex due to the number of critical processing parameters which must be monitored (e.g., residual air, pouch thickness, steam/air mixture). Labels can be printed into the laminate, making them permanent.
Flexible pouches are easier to distribute and therefore have lower transportation costs and require less disposal space.
Storage space for empty flexible pouches is also reduced. A 45 ft. trailer holds 200,000 8 oz cans or 2.3 million retort pouches.
The retort pouch system has disadvantages in processing.
The first obstacle is that processors often require a large capital investment for the unique machinery. Filling is slower and more complex compared to metal can lines.
The thermal process (steam/air, still steam, etc.) is also more complex.
The thermal process is complex due to the number of critical processing parameters which must be monitored (i.e., residual air, pouch thickness). Also, special racking systems may need to be set up in order to provide optimal heating media flow and prevent pouch to pouch contact.
Since pouches are more easily punctured they may require over-wrapping for distribution.
Specialised equipment such as a burst tester, or a tensile tester is required for leak detection and container integrity evaluation.
POUCH MATERIAL CHARACTERISTICS AND SPECIFICATIONS
The choice of materials for the manufacture of retort pouches is very important. The package must protect against light degradation, moisture changes, microbial invasion, and oxygen ingress and package interactions. The material must have sound structural integrity and be able to withstand retort temperatures as well as normal handling abuse. It must also comply with regulatory requirements. There are approximately 16 basic laminating materials with 100 different possible combinations.
Characteristics essential to a satisfactory retort pouch are:
Low gas permeability (oxygen)
Low moisture permeability
Low hydrophilic properties
Heat sealable and sterilisable
Constructed of appropriate material (material must be approved by the Canadian Food Inspection Agency (CFIA))
Resistant to penetration by fats, oils and other food components
Physical strength to resist physical abuse during packing, retorting, storage and distribution (i.e., tearing, pin-holing, fatigue, impact and abrasion)
Absence of solvent residues. Chemically inert polypropylene films require manufacturing catalysts, which must be removed with solvents before the film can be used for foods.
Bonding materials for the laminates must not migrate into the foods.
High light barrier.
A processor may purchase pouches in a number of different forms. The flexible pouches can be a pre-formed three-side sealed pouch or formed as an in-line operation with the filling and sealing combined in a pouch packager. There are several retort pouch filling and sealing systems commercially available. some retort pouches are formed from roll stock by folding a single roll along its centerline and heat sealing the sides together. The tubular material is automatically cut to length and the bottom is sealed just prior to the product filling operation.
Control of the laminate quality begins with the component material. Close control of each raw material used in the manufacture of the retort pouch must be ensured by establishing the specifications which the final laminated pouch must meet, and by establishing an effective monitoring program. Two important properties which need to be monitored during laminate fabrication are the basis weight of the laminate and the laminate tensile strength.
Basis Weight of the Laminate
The basis weight of the laminate is determined by the use of a laboratory balance. A sample of the pouch material is cut from the pouch material and weighed. The equivalent weight of the sample in grams is then converted into pounds per ream.
Note: 1 ream equals 516 sheets of paper.
Laminate Tensile Strength
The laminate tensile strength is measured using an Instron or similar tensile tester. The bond strengths of polyester film to foil, and polypropylene film to film are measured to ensure that the retort pouch material complies with the manufacturer's specifications.
Processors generally choose the pre-formed pouches. These have three seals already formed, thus requiring a single heat bar for closing. Pouches are usually transported to the plant in master cartons of 1000 or more units.
Processors inspect empty flexible pouches prior to use for: pouch dimensions, pouch shape, correct material, and manufacturer defects (i.e., delamination, abrasions, tear notch anomalies). These observations should be recorded and those pouches not meeting the manufacturer parameters must be culled out as the hermetic integrity of the pouch may be compromised.
POUCH LAMINATES
most retort pouches are constructed with a 4-ply laminate consisting of a polyester outside layer, a nylon 2nd layer, an aluminum foil 3rd layer, and a polypropylene inside layer. The aluminum foil can be laminated with either the matte or the shiny side exposed to view. Normally the matte side is to the outside. Some pouch material has polyvinylidene chloride (PVDC or SARAN®), ethylene vinyl alcohol (EVOH) or nylon instead of the aluminum foils in the middle layer. The components of the laminate are held together with adhesive, which are usually modified polyolefilms such as ethylene vinyl acetate (EVA).
Each component performs a specific function that is critical to product shelf life stability and container integrity.
In some cases a clear layer, to permit viewing of the product, replaces the foil layer. The materials of choice are generally SARAN® (PVDC), EVOH or nylon. While these plastics are good barriers to oxygen molecules, they are not complete barriers, and therefore the shelf life of the container is reduced substantially.
TYPES OF POUCHES
1 Pre-formed Pouches
The pre-formed retort pouch, which is the type most commonly used by the food processor, has three sides already sealed by the retort pouch manufacturer.
2 In-line Formed Pouches
roll stock laminate is fed through a tensioning device to ensure that the flexible pouch is smooth. A plow assembly then folds the laminate along the centerline, exposing the polypropylene surfaces to each other. (Some roll stock machines bring two separate rolls of laminate together.) The seals are formed using a heat-sealing device and the formed pouches are cut off.
One style of filler, for a liquid product, uses equipment that forms the pouch, fills and heat seals on a production-line basis. After exiting the sealer, the web of formed pouches is cut by a roller knife to separate the individual pouches.
Types of pouch designs
"V" notch design
"U" notch design
C" notch design
The U.S. Army promoted the concept of flexible retortable pouches for use in combat rations in the 1950's. The idea was to have a lightweight, easy-to-pack, shelf-stable food container in order to eliminate the heavier traditional can. Research continued through the 1960's. In 1965 the first commercial retort pouches were produced in Italy. In Japan, retort pouch technology has been widely accepted16 and there are many varied products on the shelf, ranging from sukiyaki to soup.
The retort pouch has a number of advantages compared to a metal can.
The thin profile permits a reduced heating time and thus less of a chance to overcook the product while producing better color, firmer texture and less nutrient loss. The manufacturer has reduced energy requirements for pouch production as compared to that for metal cans.14 The pouch (because of its thinner profile) transfers heat faster to its critical point. During processing, this permits the required amount of heat for proper sterilisation to reach the critical point with minimal overcooking of the product near the peripheral container areas. Thus, for those food commodities subject to quality loss from excessive heating during the process cycle, the flexible container offers the benefit of higher quality together with better retention of the heat-sensitive nutrients.
The thermal process is complex due to the number of critical processing parameters which must be monitored (e.g., residual air, pouch thickness, steam/air mixture). Labels can be printed into the laminate, making them permanent.
Flexible pouches are easier to distribute and therefore have lower transportation costs and require less disposal space.
Storage space for empty flexible pouches is also reduced. A 45 ft. trailer holds 200,000 8 oz cans or 2.3 million retort pouches.
The retort pouch system has disadvantages in processing.
The first obstacle is that processors often require a large capital investment for the unique machinery. Filling is slower and more complex compared to metal can lines.
The thermal process (steam/air, still steam, etc.) is also more complex.
The thermal process is complex due to the number of critical processing parameters which must be monitored (i.e., residual air, pouch thickness). Also, special racking systems may need to be set up in order to provide optimal heating media flow and prevent pouch to pouch contact.
Since pouches are more easily punctured they may require over-wrapping for distribution.
Specialised equipment such as a burst tester, or a tensile tester is required for leak detection and container integrity evaluation.
POUCH MATERIAL CHARACTERISTICS AND SPECIFICATIONS
The choice of materials for the manufacture of retort pouches is very important. The package must protect against light degradation, moisture changes, microbial invasion, and oxygen ingress and package interactions. The material must have sound structural integrity and be able to withstand retort temperatures as well as normal handling abuse. It must also comply with regulatory requirements. There are approximately 16 basic laminating materials with 100 different possible combinations.
Characteristics essential to a satisfactory retort pouch are:
Low gas permeability (oxygen)
Low moisture permeability
Low hydrophilic properties
Heat sealable and sterilisable
Constructed of appropriate material (material must be approved by the Canadian Food Inspection Agency (CFIA))
Resistant to penetration by fats, oils and other food components
Physical strength to resist physical abuse during packing, retorting, storage and distribution (i.e., tearing, pin-holing, fatigue, impact and abrasion)
Absence of solvent residues. Chemically inert polypropylene films require manufacturing catalysts, which must be removed with solvents before the film can be used for foods.
Bonding materials for the laminates must not migrate into the foods.
High light barrier.
A processor may purchase pouches in a number of different forms. The flexible pouches can be a pre-formed three-side sealed pouch or formed as an in-line operation with the filling and sealing combined in a pouch packager. There are several retort pouch filling and sealing systems commercially available. some retort pouches are formed from roll stock by folding a single roll along its centerline and heat sealing the sides together. The tubular material is automatically cut to length and the bottom is sealed just prior to the product filling operation.
Control of the laminate quality begins with the component material. Close control of each raw material used in the manufacture of the retort pouch must be ensured by establishing the specifications which the final laminated pouch must meet, and by establishing an effective monitoring program. Two important properties which need to be monitored during laminate fabrication are the basis weight of the laminate and the laminate tensile strength.
Basis Weight of the Laminate
The basis weight of the laminate is determined by the use of a laboratory balance. A sample of the pouch material is cut from the pouch material and weighed. The equivalent weight of the sample in grams is then converted into pounds per ream.
Note: 1 ream equals 516 sheets of paper.
Laminate Tensile Strength
The laminate tensile strength is measured using an Instron or similar tensile tester. The bond strengths of polyester film to foil, and polypropylene film to film are measured to ensure that the retort pouch material complies with the manufacturer's specifications.
Processors generally choose the pre-formed pouches. These have three seals already formed, thus requiring a single heat bar for closing. Pouches are usually transported to the plant in master cartons of 1000 or more units.
Processors inspect empty flexible pouches prior to use for: pouch dimensions, pouch shape, correct material, and manufacturer defects (i.e., delamination, abrasions, tear notch anomalies). These observations should be recorded and those pouches not meeting the manufacturer parameters must be culled out as the hermetic integrity of the pouch may be compromised.
POUCH LAMINATES
most retort pouches are constructed with a 4-ply laminate consisting of a polyester outside layer, a nylon 2nd layer, an aluminum foil 3rd layer, and a polypropylene inside layer. The aluminum foil can be laminated with either the matte or the shiny side exposed to view. Normally the matte side is to the outside. Some pouch material has polyvinylidene chloride (PVDC or SARAN®), ethylene vinyl alcohol (EVOH) or nylon instead of the aluminum foils in the middle layer. The components of the laminate are held together with adhesive, which are usually modified polyolefilms such as ethylene vinyl acetate (EVA).
Each component performs a specific function that is critical to product shelf life stability and container integrity.
In some cases a clear layer, to permit viewing of the product, replaces the foil layer. The materials of choice are generally SARAN® (PVDC), EVOH or nylon. While these plastics are good barriers to oxygen molecules, they are not complete barriers, and therefore the shelf life of the container is reduced substantially.
TYPES OF POUCHES
1 Pre-formed Pouches
The pre-formed retort pouch, which is the type most commonly used by the food processor, has three sides already sealed by the retort pouch manufacturer.
2 In-line Formed Pouches
roll stock laminate is fed through a tensioning device to ensure that the flexible pouch is smooth. A plow assembly then folds the laminate along the centerline, exposing the polypropylene surfaces to each other. (Some roll stock machines bring two separate rolls of laminate together.) The seals are formed using a heat-sealing device and the formed pouches are cut off.
One style of filler, for a liquid product, uses equipment that forms the pouch, fills and heat seals on a production-line basis. After exiting the sealer, the web of formed pouches is cut by a roller knife to separate the individual pouches.
Types of pouch designs
"V" notch design
"U" notch design
C" notch design
What is recall~
Why Recall?
It is in the best interest of suppliers and consumers to make sure that unsafe consumer products are effectively removed from the marketplace. Consumers may suffer serious injury from such products and, if they do, suppliers can be liable under the product liability provisions of the Trade Practices Act 1974 or at common law.
Under the Trade Practices Act, the Minister responsible for consumer affairs (currently the Parliamentary Secretary to the Treasurer) can order the recall of a product that will or may cause injury if the supplier has not taken satisfactory action to prevent the product causing injury to any person. However, most recalls are initiated voluntarily by manufacturers and suppliers when they become aware of a defect in a product that makes it unsafe.
This guide aims to help you, as a supplier, to recall such an unsafe product. Remember that it is important to treat a recall as a positive experience — as a chance to enhance your reputation with consumers and other key clients.
Aims of a Voluntary Recall
Your aims in voluntarily recalling an unsafe consumer product should be to:
· minimise the risk of injury or death to consumers by removing an unsafe product from use;
· retrieve or repair as many of the defective products as possible;
· minimise the cost and inconvenience to consumers and the company; and
· minimise the need for involvement by government authorities by voluntarily complying with the law.
When to recall?
You should consider a recall as soon as you become aware of a possible defect in a product that may make it unsafe. To decide if a recall is necessary:
· gather all available information on the suspected defect (eg, arrange testing, talk to consumers who have complained) and assess the reliability of that information;
· undertake a comprehensive risk analysis;
· identify how the problem occurred — consider the possibility of tampering after the product left your premises, or misuse or abuse of the product;
· look at all possible ways of addressing the defect and decide whether you can repair or modify the product; and
· decide what needs to be done.
How to recall? — a checklist
Ö Nominate one person, or a team, to examine the problem, assess the risk and coordinate the recall.
Ö Identify the steps that need to be taken to address the problem.
Ö Decide what recall action you should take, based on the risk associated with using the product. If a product is likely to cause injury, you should ask consumers and other suppliers to return the product for a refund or replacement, or for modification. If a product is unlikely to cause injury in the short term, you should invite consumers to contact the company for a replacement product or part. You should also offer to send an agent to the consumer’s home to repair or modify a product that is difficult to transport.
Ö Identify which models or batches of the product are affected (eg, by serial numbers, batch marking), when these were produced and where they have been distributed.
Ö Arrange to provide refunds, or replace or repair the defective product.
Ö Notify the Parliamentary Secretary to the Treasurer (the Minister) in writing within two days of taking recall action. Legally, this notification must state that the goods are subject to recall and provide details of the nature of any defect. Address the notification to the Minister, care of the Australian Competition and Consumer Commission (ACCC) and deliver it by post, fax or email to the ACCC at the address given below:
The Hon Chris Pearce MP Parliamentary Secretary to the Treasurer c/o: Australian Competition and Consumer Commission PO Box 1199 DICKSON ACT 2602
Fax: (02) 6243 1073 Email: recalls@recalls.gov.au
Ö Prepare a notification containing:
· a clear description of the product, including the name, make, model and serial number, with a photograph or drawing, if available;
· complete contact details of the supplier including contact name and company street address, postal address, e-mail address, web site address, telephone and facsimile numbers;
· a statement of the hazard and the associated risk;
· dates when the product was available for sale;
· the number of products affected;
· where the product has been distributed and / or exported;
· what action the supplier proposes to take
· what action the other suppliers and consumers should take; and
· detailed information about using or storing the product .
Ö Notify overseas recipients of the recalled product. If you have supplied the product overseas, you have a legal obligation to notify the recipients within a reasonable time and provide the Minister with a copy of this notification within 10 days. Address the notification to the Minister, care of the ACCC, and deliver it by post, fax or email to the ACCC at the address given above.
Ö Liaise with relevant government agencies on the recall action:
Food Standards Australia New Zealand for food recalls;
Department of Transport and Regional Services for motor vehicle recalls;
Therapeutic Goods Administration for therapeutic goods;
Australian Pesticides & Veterinary Medicines Authority (APVMA) for agricultural and veterinary chemicals;
State and Territory electrical regulators for electrical goods;
State and Territory gas regulators for gas appliance products; and
the ACCC and State and Territory consumer affairs agencies for other consumer products.
Check with the responsible authority to make sure you are aware of the correct procedures.
Ö Notify distributors, wholesalers, importers, agents and retailers quickly and in writing. If the risk is particularly serious you should, if possible, notify them directly by email, fax or telephone.
Ö Notify appropriate State and Territory authorities.
Ö Notify other companies or organisations (eg, trade associations) likely to be affected by the recall.
Ö Prepare and undertake a publicity campaign to ensure all users of the product are aware of the recall.
Ö Arrange to destroy the defective products, or store them securely until you can modify them.
Ö Keep a record of returned products, modified products, or replacement products or parts sent to consumers. Record consumer details, dates and any known injuries, damage or complaints associated with the use of the recalled good.
Ö Monitor the recall using your records of returns. If the recall has not achieved a satisfactory rate of return, you will need to develop new publicity strategies. Analyse your records to see which suppliers, or which regions, have a low return rate and choose suitable methods to inform these suppliers of the recall.
Ö Keep relevant authorities informed of the progress of the recall.
Ö Review the effectiveness of the recall procedures once the recall has finished. Put in place any changes you consider appropriate.
What type of Publicity is Best?
The traditional way of publicising recalls is to advertise in newspapers. However, you may need to consider alternative types of publicity depending on the risk associated with using the product, where the product has been distributed, and the particular consumers you want to reach. In some cases (eg, where only a few products have been sold and they can all be traced) there may be no need for a general media notice.
The best guide is to use the type of publicity most likely to get the message across to the relevant consumers quickly enough to minimise the risk of injury. You can:
· advertise in daily or community newspapers;
· display signs in retail outlets for the product;
· issue a media release to newspapers, radio and television;
· advertise on radio and television;
· advertise in retail flyers (eg, supermarkets, retail chains and department stores often send flyers to householders);
· ask relevant industry and community organisations to publicise the recall in their newsletters;
· advertise in special-interest publications if appropriate; and/or
· advertise prominently on your web site.
Guidelines on types of publicity
Media release
A media release can result in free publicity about the recall on radio, television and in newspapers, with coverage on television news or current affairs programs being particularly effective. A media release should be short, clear and written in simple language. It should contain the names, address, phone numbers and email addresses of people who can be contacted for further information.
Newspaper or magazine advertisement
Advertise the recall in newspapers published in areas where the product has been distributed.
It is important to place recall advertisements where consumers are most likely to see and read them. Place advertisements in the first five pages of newspapers, if possible, or in the public notices or the classified advertisements.
In all instances you should use the example hatched border with the safety triangle below and the recommended minimum dimensions. The ACCC recommends that recall advertisements also contain a clear description of the product, including the name, date product sold, the potential risk, and what action the consumer should take.
The following is the example of the format for a recall advertisement:
The recall advertisement should:
· be at least two columns in width, with a suggested minimum size of 10 by 12 centimetres;
· use the example hatched border with the safety triangle in the upper left-hand corner—this is an internationally recognised safety symbol;
· include the words ‘Product Safety Recall’ prominently at the top of the advertisement; and
· include the words ‘See www.recalls.gov.au for Australian Product Recall Information’ at the base of the advertisement.
Guidelines for preparing publicity material
All publicity material should include the following information:
· a clear description of the product, including the name, make, model, distinguishing features, batch or serial number;
· a drawing or photograph of the product if available;
· clear identification of the supplier, including logo, trademark or letterhead, street, postal, e-mail and web site address, fax and telephone number;
· a statement of the hazard and the associated risk;
· dates when the product was available for sale;
· what immediate action consumers should take (eg, cease use, store safely);
· who consumers should contact to receive a refund or have the product repaired or replaced (eg, manufacturer, wholesaler, agent or retailer);
· business and after hours telephone numbers for further information, preferably toll-free; and
· advice that the recall is at the expense of the supplier.
How The ACCC can help with your recall
The ACCC can help you by providing guidance on recall procedures, advising on the type of publicity suitable for your recall, and posting your recall to the Product Recalls Australia web site at www.recalls.gov.au.
It is in the best interest of suppliers and consumers to make sure that unsafe consumer products are effectively removed from the marketplace. Consumers may suffer serious injury from such products and, if they do, suppliers can be liable under the product liability provisions of the Trade Practices Act 1974 or at common law.
Under the Trade Practices Act, the Minister responsible for consumer affairs (currently the Parliamentary Secretary to the Treasurer) can order the recall of a product that will or may cause injury if the supplier has not taken satisfactory action to prevent the product causing injury to any person. However, most recalls are initiated voluntarily by manufacturers and suppliers when they become aware of a defect in a product that makes it unsafe.
This guide aims to help you, as a supplier, to recall such an unsafe product. Remember that it is important to treat a recall as a positive experience — as a chance to enhance your reputation with consumers and other key clients.
Aims of a Voluntary Recall
Your aims in voluntarily recalling an unsafe consumer product should be to:
· minimise the risk of injury or death to consumers by removing an unsafe product from use;
· retrieve or repair as many of the defective products as possible;
· minimise the cost and inconvenience to consumers and the company; and
· minimise the need for involvement by government authorities by voluntarily complying with the law.
When to recall?
You should consider a recall as soon as you become aware of a possible defect in a product that may make it unsafe. To decide if a recall is necessary:
· gather all available information on the suspected defect (eg, arrange testing, talk to consumers who have complained) and assess the reliability of that information;
· undertake a comprehensive risk analysis;
· identify how the problem occurred — consider the possibility of tampering after the product left your premises, or misuse or abuse of the product;
· look at all possible ways of addressing the defect and decide whether you can repair or modify the product; and
· decide what needs to be done.
How to recall? — a checklist
Ö Nominate one person, or a team, to examine the problem, assess the risk and coordinate the recall.
Ö Identify the steps that need to be taken to address the problem.
Ö Decide what recall action you should take, based on the risk associated with using the product. If a product is likely to cause injury, you should ask consumers and other suppliers to return the product for a refund or replacement, or for modification. If a product is unlikely to cause injury in the short term, you should invite consumers to contact the company for a replacement product or part. You should also offer to send an agent to the consumer’s home to repair or modify a product that is difficult to transport.
Ö Identify which models or batches of the product are affected (eg, by serial numbers, batch marking), when these were produced and where they have been distributed.
Ö Arrange to provide refunds, or replace or repair the defective product.
Ö Notify the Parliamentary Secretary to the Treasurer (the Minister) in writing within two days of taking recall action. Legally, this notification must state that the goods are subject to recall and provide details of the nature of any defect. Address the notification to the Minister, care of the Australian Competition and Consumer Commission (ACCC) and deliver it by post, fax or email to the ACCC at the address given below:
The Hon Chris Pearce MP Parliamentary Secretary to the Treasurer c/o: Australian Competition and Consumer Commission PO Box 1199 DICKSON ACT 2602
Fax: (02) 6243 1073 Email: recalls@recalls.gov.au
Ö Prepare a notification containing:
· a clear description of the product, including the name, make, model and serial number, with a photograph or drawing, if available;
· complete contact details of the supplier including contact name and company street address, postal address, e-mail address, web site address, telephone and facsimile numbers;
· a statement of the hazard and the associated risk;
· dates when the product was available for sale;
· the number of products affected;
· where the product has been distributed and / or exported;
· what action the supplier proposes to take
· what action the other suppliers and consumers should take; and
· detailed information about using or storing the product .
Ö Notify overseas recipients of the recalled product. If you have supplied the product overseas, you have a legal obligation to notify the recipients within a reasonable time and provide the Minister with a copy of this notification within 10 days. Address the notification to the Minister, care of the ACCC, and deliver it by post, fax or email to the ACCC at the address given above.
Ö Liaise with relevant government agencies on the recall action:
Food Standards Australia New Zealand for food recalls;
Department of Transport and Regional Services for motor vehicle recalls;
Therapeutic Goods Administration for therapeutic goods;
Australian Pesticides & Veterinary Medicines Authority (APVMA) for agricultural and veterinary chemicals;
State and Territory electrical regulators for electrical goods;
State and Territory gas regulators for gas appliance products; and
the ACCC and State and Territory consumer affairs agencies for other consumer products.
Check with the responsible authority to make sure you are aware of the correct procedures.
Ö Notify distributors, wholesalers, importers, agents and retailers quickly and in writing. If the risk is particularly serious you should, if possible, notify them directly by email, fax or telephone.
Ö Notify appropriate State and Territory authorities.
Ö Notify other companies or organisations (eg, trade associations) likely to be affected by the recall.
Ö Prepare and undertake a publicity campaign to ensure all users of the product are aware of the recall.
Ö Arrange to destroy the defective products, or store them securely until you can modify them.
Ö Keep a record of returned products, modified products, or replacement products or parts sent to consumers. Record consumer details, dates and any known injuries, damage or complaints associated with the use of the recalled good.
Ö Monitor the recall using your records of returns. If the recall has not achieved a satisfactory rate of return, you will need to develop new publicity strategies. Analyse your records to see which suppliers, or which regions, have a low return rate and choose suitable methods to inform these suppliers of the recall.
Ö Keep relevant authorities informed of the progress of the recall.
Ö Review the effectiveness of the recall procedures once the recall has finished. Put in place any changes you consider appropriate.
What type of Publicity is Best?
The traditional way of publicising recalls is to advertise in newspapers. However, you may need to consider alternative types of publicity depending on the risk associated with using the product, where the product has been distributed, and the particular consumers you want to reach. In some cases (eg, where only a few products have been sold and they can all be traced) there may be no need for a general media notice.
The best guide is to use the type of publicity most likely to get the message across to the relevant consumers quickly enough to minimise the risk of injury. You can:
· advertise in daily or community newspapers;
· display signs in retail outlets for the product;
· issue a media release to newspapers, radio and television;
· advertise on radio and television;
· advertise in retail flyers (eg, supermarkets, retail chains and department stores often send flyers to householders);
· ask relevant industry and community organisations to publicise the recall in their newsletters;
· advertise in special-interest publications if appropriate; and/or
· advertise prominently on your web site.
Guidelines on types of publicity
Media release
A media release can result in free publicity about the recall on radio, television and in newspapers, with coverage on television news or current affairs programs being particularly effective. A media release should be short, clear and written in simple language. It should contain the names, address, phone numbers and email addresses of people who can be contacted for further information.
Newspaper or magazine advertisement
Advertise the recall in newspapers published in areas where the product has been distributed.
It is important to place recall advertisements where consumers are most likely to see and read them. Place advertisements in the first five pages of newspapers, if possible, or in the public notices or the classified advertisements.
In all instances you should use the example hatched border with the safety triangle below and the recommended minimum dimensions. The ACCC recommends that recall advertisements also contain a clear description of the product, including the name, date product sold, the potential risk, and what action the consumer should take.
The following is the example of the format for a recall advertisement:
The recall advertisement should:
· be at least two columns in width, with a suggested minimum size of 10 by 12 centimetres;
· use the example hatched border with the safety triangle in the upper left-hand corner—this is an internationally recognised safety symbol;
· include the words ‘Product Safety Recall’ prominently at the top of the advertisement; and
· include the words ‘See www.recalls.gov.au for Australian Product Recall Information’ at the base of the advertisement.
Guidelines for preparing publicity material
All publicity material should include the following information:
· a clear description of the product, including the name, make, model, distinguishing features, batch or serial number;
· a drawing or photograph of the product if available;
· clear identification of the supplier, including logo, trademark or letterhead, street, postal, e-mail and web site address, fax and telephone number;
· a statement of the hazard and the associated risk;
· dates when the product was available for sale;
· what immediate action consumers should take (eg, cease use, store safely);
· who consumers should contact to receive a refund or have the product repaired or replaced (eg, manufacturer, wholesaler, agent or retailer);
· business and after hours telephone numbers for further information, preferably toll-free; and
· advice that the recall is at the expense of the supplier.
How The ACCC can help with your recall
The ACCC can help you by providing guidance on recall procedures, advising on the type of publicity suitable for your recall, and posting your recall to the Product Recalls Australia web site at www.recalls.gov.au.
Saturday, April 7, 2007
Recommendations of ensuring food safety~
Recommendation of ensuring safety of pound cake: 1 Maintaining Good personal Hygiene.As human are the major source of food contamination.Food workers must observe the highest possible standards of personal hygiene to make certain that food does not become contaminated by pathogenic microorganisms, physical or chemical hazards. High standards of personal hygiene also play an important part in creating a good public image, as well as protecting food. Poor handwashing is one of the leading causes of foodborne illness. Standard operating procedures for the correct handwashing method / safe hands procedure should be taught to workers.For example: Workers should wash their hands clean and use a glove while working with food products, both raw and cooked. 2 Keeping the area of working place aseptic and clean. Also it is important to maintain the cleanliness of the equipments and machines used to handle the product, while also keeping them thoroughly sanitized. 3 Checking computerized or automated time and temperature devices.Check the equipment regularly. We can reduce bacterial growth in potentially hazardous foods by limiting the time food is in the "danger zone" (140 F to 41 F) during any steps of the food flow from receiving through service. The FDA Food Code recommendation no more than a cumulative 4 hours in the danger zone. For example: The temperature of freezer and the time-temperature of the oven while baking. Make sure they are working at accurate and optimum level. 4 Avoid cross-contamination from:a. Raw food to cooked foodb. Equipment to foodc. Work surface to foodd. People to food
5 Set up of HACCP programme: the programme is designed to accommodate the types of products produced , the production equipment and the process of production., and to identify problem areas and take action to ensure the food production is safe for consumption.
6 Quality check of the ingredients upon receiving: Make sure that the ingredients are bought from reliable suppliers and check for Certificate of analysis(COA). Checking for :physical quality , chemical quality, microbial quality, shelf life under specified storage condition, packaging format and delivery mode.
7 Proper storage of the ingredients to reduce the chance of contamination and deterioration by : eliminating pest, prohibiting or preventing the growth of microorganism, control chemical and physical deterioration by excluding air or oxygen , light , deleterious/harmful contaminants. Practice first-in-first-out(FIFO) principle to allow stock rotation and ensure freshness of the ingredients.
8 Environment control : The moisture level and temperature and ventilation condition of the production area and storage room should be closely monitored.
Improper holding temperatures,
Inadequate cooking, such as undercooking raw shell eggs,
Contaminated equipment,
Food from unsafe sources,
Poor personal hygiene, and
Others (such as, pest and rodent infestation and improper food storage).
5 Set up of HACCP programme: the programme is designed to accommodate the types of products produced , the production equipment and the process of production., and to identify problem areas and take action to ensure the food production is safe for consumption.
6 Quality check of the ingredients upon receiving: Make sure that the ingredients are bought from reliable suppliers and check for Certificate of analysis(COA). Checking for :physical quality , chemical quality, microbial quality, shelf life under specified storage condition, packaging format and delivery mode.
7 Proper storage of the ingredients to reduce the chance of contamination and deterioration by : eliminating pest, prohibiting or preventing the growth of microorganism, control chemical and physical deterioration by excluding air or oxygen , light , deleterious/harmful contaminants. Practice first-in-first-out(FIFO) principle to allow stock rotation and ensure freshness of the ingredients.
8 Environment control : The moisture level and temperature and ventilation condition of the production area and storage room should be closely monitored.
Improper holding temperatures,
Inadequate cooking, such as undercooking raw shell eggs,
Contaminated equipment,
Food from unsafe sources,
Poor personal hygiene, and
Others (such as, pest and rodent infestation and improper food storage).
Tuesday, April 3, 2007
What i hav done so far~
11. What spoilage does it cause to pound cakes and what steps should be reinforced?
The Avian flu will infect the chicken.The Virus will pass to human via poultry products,which will cause food borne disease .In this recipe, whole eggs and egg yolks are used as ingredients, fresh shell eggs may contain certain bacteria that can cause foodborne illness. The bacteria are Salmonella enteritidis, which will make people more vulnerable to food borne disease. Storing the eggs and egg yolks in refrigerator at 2-4’C ,this step should be reinforced.The temperature should be closely monitored in order to keep the eggs and egg yolks out of the temperature danger zone, that will prevent the eggs from spoiling and the microbes from growing. Keeping eggs adequately refrigerated prevents any Salmonella present in the eggs from growing to higher numbers, so eggs should be held refrigerated until they are needed
Handle Eggs Safely—Wash hands, utensils, equipment and work areas with warm, soapy water before and after contact with eggs and egg-rich foods. Which will minimize the chance of cross contamination, and not be held in the temperature range of 40 to 140 for more than 2 hours.
Baking for 1 hour at 170’C---The baking temperature should be high enough to kill the bacteria.
12. How should we store ingredients which are highly susceptible to these bacteria to stop it from spreading to other ingredients?
Buy Clean Eggs—At the store, choose Grade A or AA eggs with clean, uncracked shells. Make sure they've been refrigerated in the store. Any bacteria present in an egg can multiply at room temperature.
Refrigerate Eggs—Take eggs straight home and store them immediately in the refrigerator set at 40°F or slightly below. Store them in the grocery carton in the coldest part of the refrigerator, not in the door. Don't wash eggs. That could increase the potential for bacteria on the shell to enter the egg.
Use Eggs Promptly—Use raw shell eggs within 3 to 5 weeks. Hard-cooked eggs will keep refrigerated one week. Use leftover yolks and whites within 4 days.If eggs crack on the way home from the store, break them into a clean container, cover it tightly, and keep refrigerated for use with in 2 days.
Freeze Eggs for Longer Storage—Eggs should not be frozen in their shells. To freeze whole eggs, beat yolks and whites together. Egg whites can be frozen by themselves. Use frozen eggs within a year.If eggs freeze accidentally in their shells, keep them frozen until needed. Defrost them in the refrigerator. Discard any with cracked shells.
The Avian flu will infect the chicken.The Virus will pass to human via poultry products,which will cause food borne disease .In this recipe, whole eggs and egg yolks are used as ingredients, fresh shell eggs may contain certain bacteria that can cause foodborne illness. The bacteria are Salmonella enteritidis, which will make people more vulnerable to food borne disease. Storing the eggs and egg yolks in refrigerator at 2-4’C ,this step should be reinforced.The temperature should be closely monitored in order to keep the eggs and egg yolks out of the temperature danger zone, that will prevent the eggs from spoiling and the microbes from growing. Keeping eggs adequately refrigerated prevents any Salmonella present in the eggs from growing to higher numbers, so eggs should be held refrigerated until they are needed
Handle Eggs Safely—Wash hands, utensils, equipment and work areas with warm, soapy water before and after contact with eggs and egg-rich foods. Which will minimize the chance of cross contamination, and not be held in the temperature range of 40 to 140 for more than 2 hours.
Baking for 1 hour at 170’C---The baking temperature should be high enough to kill the bacteria.
12. How should we store ingredients which are highly susceptible to these bacteria to stop it from spreading to other ingredients?
Buy Clean Eggs—At the store, choose Grade A or AA eggs with clean, uncracked shells. Make sure they've been refrigerated in the store. Any bacteria present in an egg can multiply at room temperature.
Refrigerate Eggs—Take eggs straight home and store them immediately in the refrigerator set at 40°F or slightly below. Store them in the grocery carton in the coldest part of the refrigerator, not in the door. Don't wash eggs. That could increase the potential for bacteria on the shell to enter the egg.
Use Eggs Promptly—Use raw shell eggs within 3 to 5 weeks. Hard-cooked eggs will keep refrigerated one week. Use leftover yolks and whites within 4 days.If eggs crack on the way home from the store, break them into a clean container, cover it tightly, and keep refrigerated for use with in 2 days.
Freeze Eggs for Longer Storage—Eggs should not be frozen in their shells. To freeze whole eggs, beat yolks and whites together. Egg whites can be frozen by themselves. Use frozen eggs within a year.If eggs freeze accidentally in their shells, keep them frozen until needed. Defrost them in the refrigerator. Discard any with cracked shells.
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