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QUALITY PARTNERS COMPANY, Ltd.

FOOD SAFETY PROGRAMS


IN FISH PROCESSING:
FROM FARM TO FORK
RINGIER EVENTS
2nd FOOD AND BEVERAGE SUMMIT
JS Luwansa Hotel and Convention Center
Jakarta, Indonesia, Nov. 7-8, 2016
Keynote Speaker:
Dr. Miflora M. Gatchalian, CEO QPCL
ACADEMICIAN EMERITUS, International Academy

for Quality ( IAQ)

FOOD SAFETY PROGRAMS


IN FISH PROCESSING: FROM FARM TO FORK
ABSTRACT

Appropriate fish post-harvest technologies are necessary to


ensure the delivery of good quality and safe products to the
market. It is thus, urgent to follow food safety programs
in fish processing to ensure safe products from farm to
fork. Globalization requires a harmonized system of food
inspection with focus on food safety. In this regard, food
safety programs such as (a) Good Manufacturing Practices
(GMP); (b) Sanitation Standard Operating Procedures
(SSOP) and (c) Hazard Analysis, Critical Control Point
(HACCP) had been accepted as standard programs by the
European Union, Canada, Australia, New Zealand, USA,
Japan and many ASEAN Countries.

Fish lapu-lapu in
crushed ice

Crustaceans shrimp,
lobster, etc.

Seafood include fish and crustaceans


harvested from the sea.
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Mari-culture
Fish Cages

Feeding House

Cage:
6X6X5

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GOOD MANUFACTURING PRACTICES


BANGUS DEBONING AT
ANJO FARMS,
PANGASINAN
( GMP-IMPLEMENTED)

PROCESSING
CONDITIONS
AFTER ONE YEAR
OF GMPSSOP HACCP
DEVELOPMENT

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PROCESSED SEA
FOODS EITHER BY
DRYING OR CANNING.
PROPER PACKAGING
PLAYS AN IMPORTANT
ROLE IN FOOD SAFETY

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Fostering Partnerships Through

STANDARD FOOD SAFETY PROGRAMS

GMP Good Manufacturing


Practice

SSOP Sanitation Standard


Operating Procedures

HACCP Hazard Analysis and


Critical Control Point
3. 2

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The scope of Food Plant


Sanitation includes:
Plant Building and Design
Sanitary Facilities
Personnel Hygiene and Health
requirements
Personnel Practices and Clothing
Cleaning and Disinfection
Methods
Pest Control
Maintenance Schedule
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GOOD MANUFACTURING
PRACTICES
CLEAN
CEILINGS,
CLEAN
WORK
TABLES

AND
FLOORS

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SOME EVIDENCES OF GOOD PERSONNEL HYGIENE

Workers in complete uniform using clean crushed ice - always


available to keep fish cool while in process before freezing
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From : MMGs DOST-MPEX


Project

Clean comfort rooms with


wash basins, detergent and
dryer (seen reflected in mirror)

Foot bath using chlorinated


water (200 PPM) before entry
into the processing plant.

Some evidences of sanitary practices in the company


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GMP Rules in Food Plant


Personnel cleanliness

NO RINGS AND JEWELRY PERMITTED


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SANITATION STANDARD OPERATING PROCEDURES (SSOP)

SSOP 8 CONDITIONS: SCPH- PLEE


SAFETY OF WATER
CLEANLINESS OF CONTACT SURFACES
PREVENTION FROM CROSS-CONTAMINATION
HANDWASHING AND TOILET FACILITIES

PROTECTION FROM ADULTERANTS


LABELLING, STORAGE AND USE OF TOXIC CHEMICALS
EMPLOYEES HEALTH
EXCLUSION OF PESTS
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SCPH-PLEE

SAFETY OF WATER

It is important to show good examples and bad


examples as shown below

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Step-1- De-scaling and


washing

Step-2- Eviscerating and


beheading

Step-4- Layering and


inspection of fillets

Step-5- Layering and Sizing

Step-3- Filleting and


removal of left-over skin

Step-6- Vacuum packaging


& blast freezing at 35 to
40o C for 34 hours.

EXAMPLE: New Product - Process flow for Sayori fillet


specifically developed by FTs for the Japanese market
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SCPH

PREVENTION

OF CROSS-CONTAMINATION

SNEEZE ? ? ?

BE CAREFUL

SCPH-

4-HANDWASHING,

SANITIZING and TOILET FACILITIES

ELBOW FAUCET CONTROL

FOOT PEDAL TO OPEN FAUCETS

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CROSS CONTAMINATION

FOOD TO FOOD
EQUIPMENT TO FOOD
PEOPLE TO FOOD
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PLEE

6- LABELING, STORAGE AND USE OF TOXIC COMPOUNDS

Proper Labeling,
Storage, and Use of
Toxic Compounds

NEVER! Containers used to


hold Cleaners & sanitizers
must not be USED as food
containers
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PLEE

7- EMPLOYEE HEALTH CONDITION

STOMACH
PROBLEM ???

WOUND???
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PLEE

EXCLUSION OF RODENTS & PESTS

Goal:
Monitoring must confirm that pests are excluded
from relevant areas of the plant to the extent
possible and should also confirm that procedures

are followed to prevent infestation.

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7 - HACCP Principles ( IDD MCVR)

1
2
3
4
5

Identify the hazards through analysis


Determine the Critical Control Points (CCPs).
Determine critical limits at the CCP
Monitor systematic control at the CCP.

Corrective actions to be taken when monitoring


indicates that a particular CCP is not under control.

Verification of procedures established to confirm


that the HACCP system is working effectively.

Records appropriate to the principles and


documentation concerning all procedures established.

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1
2
3
4
5
6

Assemble HACCP Team


Describe Product

12 Tasks

Identify Intended Use


Construct Flow Diagram

CONDUCT THE
On-Site Confirmation of Flow Diagram
HACCP STUDY
List all potential hazards associated with each step,
conduct a hazard analysis, and consider any
measures to control identified hazards

Determine Critical Control Points (CCP)

ESTABLISH
THE HACCP
PLAN

8
9
10
11
12

Establish critical limits for each CCP


Establish a monitoring system for each CCP
Establish corrective actions
Establish verification procedures
Establish Documentation and Record Keeping
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Fig. 2. Important process flow for determination of critical control point


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PRODUCT
PROCESS FLOW :

DRIED SHRIMP
Quality Control Point (Q.C.P.)

Receiving Shrimp Head on

Check Sulfite*
Residual ( R = O )

Iced Shrimp Storage

Below 35o to 40oF

Wash & Weigh Raw Shrimp

Temperature* : 160o +/- 5oF

Forced Air Dry

M.C. = 10-15% , Aw < 0.65

Screen Tumbling

SSOP (Sanitation Standard


Operating Procedure)

STORAGE

CHEMICAL

Chlorinated Water ( >10 ppm )

Cook Shrimp

Packaging or Sacking

HAZARD

Metal Detector*
Check seal
20o 25oC

MICROBIO

PHYSICAL

*C.C.P.

Fig. 4. Process flow diagram for dried shrimp (modified from NSHA, 2000)

Example: for Illustrative Purposes Only* - HACCP Plan Form (Worksheet VII)

(1)
Critical Control
Point (CCP)

(2)
Significant
Hazard(s)

(3)
Critical Limits
for each Control
Measures

(4)

(5)

(6)

(7)

Frequency

Who

Monitoring
What

Firm Name: __________________________________________________________

How

(8)
Corrective
Action(s)

(9)
Verification

(10)
Records

Product Description: ______________________________________________________________________

Firm Address: ________________________________________________________

___________________________________________________________________________________________

_______________________________________________________________________

Method of Storage and Distribution: _____________________________________________________

_______________________________________________________________________

___________________________________________________________________________________________

Signature: ____________________________________________________________

Intended Use and Consumer: _____________________________________________________________

Date : _________________________________________________________________

____________________ _______________________________________________________________________

Quality Partners Company Ltd.

SUMMARY
Fish is one of the most perishable food since its deterioration immediately starts
as soon as it is harvested from water. Onset of spoilage is accelerated under
unsanitary post-harvest conditions or inadequate equipment. Therefore, application of
appropriate fish post harvest technologies are necessary to ensure the delivery of good
quality and safe products to the market.
With globalization and the on-going liberalization on international trade, the need to
establish a harmonized system of food inspection with focus on achieving food
safety has become very urgent. This also prompted importing countries to tighten
quality requirements and revise food sanitation laws and hygienic standards A
HACCP-based approach to produce safe food had been accepted as a standard system
by the European Union , Canada, Australia, New Zealand, Japan and many ASEAN
countries for their own industry and for those who export to these countries In fact,
they have developed well-organized Food Safety Programs for fish processing such
as: (a) Good Manufacturing Practices; (b) Sanitation Standard Operating Procedures
and (c ) Hazard Analysis Critical Control Point (HACCP). These are basic to
implementation of International Standards of Food Safety such as ISO 22000
Food Safety Management System (FSMS) or the International Food Safety Quality
Networks
FSSC- 22000.

I SINCERELY THANK
RINGIER EVENTS, the organizers of the
2ND ASIAN FOOD AND BEVERAGE
SUMMIT
for having given me the opportunity to
To participate as Speaker in this noble
undertaking
Dr. Miflora M. Gatchalian
CEO, QPCL
<qpcl.gatch@gmail.com>

Quality Partners Company Ltd.