HACCP Manual SPC Coconuts March 2019 - Web

190304 HACCP Manual SPC Coconuts March 2019.
docx Page 1 of 83
Forward
This Manual has been prepared for the Coconut Industry Development for the Pacific
Programme which is currently administered under the Pacific Community. The Manual has
been compiled from the works of various coconut and HACCP experts in the field, by
Apiame Cegumalua and Viola Lesi both consultants for HACCP Australia Fiji Ltd. of Suva,
Fiji and edited by David Haberfield of HACCP Australia. The Manual is intended to be
used as a training tool and a guide for trainers in the coconut industry. This Manual is
solely the property of the Secretariat of the Pacific Community.
Acknowledgment
We would like to thank the Team Leader Naheed Hussain for giving us the opportunity to
work on this project.
190304 HACCP Manual SPC Coconuts March 2019.docx Page 2 of 83

Table of Contents
Forward ............................................................................................................................................................ 2
Acknowledgment .............................................................................................................................................. 2
Table of Contents ............................................................................................................................................. 3
Table of Figures ............................................................................................................................................... 4
Definitions and Abbreviations ........................................................................................................................... 5
Introduction....................................................................................................................................................... 8
Module 1: Introduction to Hazard Analysis Critical Control Point and Risk Management Strategy................ 10
Risk Management Strategy (RMS) is based on three basic principles......................................................................... 10
HACCP ......................................................................................................................................................................... 11
Advantages of HACCP ................................................................................................................................................. 12
Description of the HACCP System ............................................................................................................................... 12
Flowchart for the HACCP system................................................................................................................................. 13
Implementing the HACCP method .............................................................................................................................. 15
The Preparatory phase:............................................................................................................................................... 16
Implementation phase ................................................................................................................................................ 17
Establishing Critical Limits .......................................................................................................................................... 22
Critical Control Point Monitoring ................................................................................................................................ 23
Prerequisite programs (PRP) ....................................................................................................................................... 24
Module 2: Hazards ......................................................................................................................................... 26
.1 Definition of Hazard .......................................................................................................................................... 26
.2 Why hazard analysis is conducted? ................................................................................................................... 26
.3 Types of Hazards: .............................................................................................................................................. 26
.4 The Five Steps in a Hazard Analysis ................................................................................................................... 27
.5 Control measures .............................................................................................................................................. 27
Module 3: Coconut Products .......................................................................................................................... 28
COCONUT OIL.............................................................................................................................................................. 28
COCONUT BUTTER ...................................................................................................................................................... 29
DESICCATED/SHREDDED/FLAKED COCONUT .............................................................................................................. 30
COCONUT FLOUR ........................................................................................................................................................ 31
COCONUT MILK ........................................................................................................................................................... 32
COCONUT WATER ....................................................................................................................................................... 33
COCONUT SUGAR........................................................................................................................................................ 34
COCONUT NECTAR ...................................................................................................................................................... 34
COCONUT AMINOS ..................................................................................................................................................... 35
COCONUT VINEGAR .................................................................................................................................................... 35
Module 4: GMP (Good Manufacturing Practice) ............................................................................................ 36
Module 5: Cleaning & Sanitation .................................................................................................................... 38
Key Steps in Cleaning .................................................................................................................................................. 41
Module 6 PRP’s Prerequisite or Support Systems ......................................................................................... 43
PRP - Approved Supplier Program ............................................................................................................................... 44
PRP - SITE Standard: Building, Infrastructure and Premises ....................................................................................... 45
PRP - Transportation Receiving and Storage .............................................................................................................. 45
PRP - Chemical Receival / Storage and Safe Handling ................................................................................................ 45
PRP - Cleaning/Sanitation ........................................................................................................................................... 45
PRP - Good Hygienic Practice (GHP)............................................................................................................................ 46
PRP - Pest Control ....................................................................................................................................................... 47
PRP - Training.............................................................................................................................................................. 48
PRP - Document Control .............................................................................................................................................. 49
PRP - Product Identification and Traceability.............................................................................................................. 50
PRP – Product Recall ................................................................................................................................................... 50
PRP - Mock Recall........................................................................................................................................................ 50
PRP - Allergen Control ................................................................................................................................................. 51
PRP - Labelling ............................................................................................................................................................ 51
PRP - Visitors Policy ..................................................................................................................................................... 52

PRP - Maintenance...................................................................................................................................................... 53
PRP - Calibration ......................................................................................................................................................... 54
PRP - Verification ........................................................................................................................................................ 55
PRP - Auditing ............................................................................................................................................................. 55
PRP – Corrective Action system and complaints ......................................................................................................... 55
PRP - Organic Systems ................................................................................................................................................ 56
PRP - Food Defence - TACCP & VACCP ........................................................................................................................ 56
Module 7: Traceability & Recall ...................................................................................................................... 57
Module 8: Quality ........................................................................................................................................... 60
References ..................................................................................................................................................... 64
Appendix ........................................................................................................................................................ 65
Appendix 1: Virgin Coconut Oil (VCO) - Dry Process .................................................................................................... 65
Appendix 2: Example Product Description – Virgin Coconut Oil............................................................................... 66
Appendix 3: Example – Flow Chart Hazard Analysis – Virgin Coconut Oil................................................................ 67
Appendix 4: Example – Hazard Analysis – Virgin Coconut Oil ..................................................................................... 68
Appendix 5: Example – HACCP Plan – Virgin Coconut Oil ........................................................................................ 81
Appendix 6: Example – CCP Determination Questions – Virgin Coconut Oil ............................................................... 83
Table of Figures
Figure 1: Principles of HACCP ........................................................................................... 12
Figure 2: Flowchart of the HACCP system ........................................................................ 14
Figure 3: HACCP Application ............................................................................................. 15
Figure 5: Basic HACCP Flowchart ..................................................................................... 17
Figure 6: HACCP Risk Matrix............................................................................................. 18
Figure 7: CCP Decision Tree ............................................................................................. 19
Figure 8: The Complete HACCP Process .......................................................................... 24
Figure 9: The Complete HACCP Process .......................................................................... 41
Figure 10: Traceability Flow chart ................................................................................... 57
Figure 11: Traceability Flow chart – between processed ................................................ 59

Definitions and Abbreviations
Term Definition
°C Celsius
AUDIT A systematic evaluation of activities and processes to
confirm that objectives are being met.
CALIBRATION Calibration in measurement technology and metrology is the
comparison of measurement values delivered by a device
under test with those of a calibration standard of known
accuracy. Strictly speaking, the term calibration means
just the act of comparison, and does not include any
subsequent adjustment
CCP DECISION TREE A tool that helps you decide whether a hazard control point
is a critical control point or not. A critical control point (CCP)
is a step at which control can be applied.
CLEAN IN PLACE (CIP) A cleaning system for pipes or equipment where cleaning is
achieved by circulating a suitable cleaning solution around
the system using turbulence to provide effective cleaning
CONTROL POINT (CP) Any point or step in a process where control can be
achieved.
CORRECTIVE ACTION Action taken to regain control where critical limits have not
been met and to prevent recurrence of the deviation.
CRITICAL CONTROL A critical step at which an action or procedure can be taken
POINT (CCP) to eliminate a hazard or reduce it to a level where it is no
longer a food/product safety risk.
CRITICAL LIMIT (CL) Critical Limit. A specification and/or value, which separates
acceptability from unacceptability.
DEVIATION A non-conformity or failure to meet Critical Limits.
FLOWCHART Chart to provide an outline of key steps in a Process
FOOD DEFENCE Food Defence is having plans in place to reduce the
chances of someone intentionally contaminating the food
supply in order to kill or harm people, disrupt the economy
or destroy a business.
FOOD FRAUD Food fraud is a collective term used to encompass the
deliberate and intentional substitution, addition, tampering,
or misrepresentation of food, food ingredients, or food
packaging; or false or misleading statements made about a
product, for economic gain.
FSANZ Food Standards Australia and New Zealand.
GAP Good Agricultural Practices
GHP Good Hygiene Practices
GMP Good Manufacturing Practices
HACCP Hazard Analysis Critical Control Point
HACCP AUDIT TABLE A table documenting the critical limits, monitoring criteria,
corrective actions and associated SOP’s or references for
each of the CCP’s and QCP’s.
HACCP PLAN The written document based upon the Principles of HACCP,
which describes the procedures which must be followed to
assure control of a specific procedure or process.

Term Definition
HACCP SYSTEM Identification of specific hazards and preventive measures
for their control.
HAZARD A biological, chemical or physical agent that will cause the
product to be unsafe for consumption. The consequence or
impact and likelihood of each hazard are plotted on a
Qualitative Risk Analysis Matrix which is used to determine
if the hazard is significant and whether or not it should be
considered as a Critical Control Point.
LIKLIHOOD The probability that the hazard will occur
MONITORING Describes how to carry out monitoring procedures for each
of the CCP’s and QCP’s. To conduct a planned system of
observation or measurement to assess control of a CCP or
QCP and to make accurate records for verification in the
future.
MSDS Material Safety Data Sheet
NASA National Aeronautics and Space Administration
NIP Nutritional Information Panel
NON-CONFORMING A deviation from accepted procedures or critical limits.
NZFST New Zealand Food Standard
ORGANIC Organic farming is the production of food without the use of
synthetic chemicals or genetically modified components.
Organic farming is better for the environment and more
sustainable
PATHOGENS Microbes capable of causing disease in humans.
pH Alkalinity and Acidity unit
PREREQUISITE The universal procedures used to control the conditions in
PROGRAM (PRP) the plant environment which contribute to overall safety of
the product. Also known as Support Systems
PREVENTIVE Actions or equipment, which can be used to control a
MEASURES hazard.
PRP Pre -Requisite Program
QUALITY CONTROL A point in a process at which control is required to prevent,
POINT (QCP) eliminate or minimize a quality hazard
QUALITY CONTROL A point in a process at which control is required to prevent,
POINT (QCP) eliminate or minimize a quality hazard.
RE-WORK An unincorporated food product kept for subsequent use or
re-processing at a later stage.
RISK MATRIX A matrix used to rank and compare the Significance of
Hazards based on ranking Severity against Likelihood
RMS Risk Management System
SEVERITY The seriousness of the effect of a hazard
SHELF-LIFE The time period within which the food is safe to consume
and/or has an acceptable quality to consumers.
Support Systems The universal procedures used to control the conditions in
the plant environment which contribute to overall safety of
the product. Also known as PRP’s or Prerequisite Programs
TACCP Threat Analysis Critical Control Point
USA United States of America
VACCP Vulnerability Analysis Critical Control Point

Term Definition
VALIDATION The process used to ensure the critical limits identified for
each of the CCP’s in the program are effective. The
validation process requires evidence such as scientific
evidence (investigative or experimental of processes:
studies) to determine whether the control measures are
capable of controlling the hazards and ensuring that the end
product is safe.
VCO Virgin Coconut Oil
VERIFICATION Methods, procedures or tests in addition to those used in
monitoring to determine the compliance of the HACCP
SYSTEM and/or whether or not the HACCP AUDIT TABLE
needs modification.

Introduction
The Pacific Island people have had a long association with coconuts products not only as a
food item but now specifically as a potential marketable commodity. The fact remains that
the Pacific Island coconut growing nations are small in land mass, isolated and scattered in
the vast ocean where transportation and infrastructure are costly to maintain. The coconut
product however is of high value and can be targeted at the high-end market. A total of
589,000 hectares of land is currently utilised for coconuts in the Pacific Islands, Papua New
Guinea, being the major producer comprising 37% of the total Pacific Island growing area.
Coconut farms are mainly village based and processing techniques are mostly traditional
which has been passed down through years of generation with very basic equipment.
However according to Uron Salum, (APCC Executive Director at a CIDP Meeting on July
2019), the market information shows that in the last 5 years commercial utilisation of
Coconut products has increased exponentially and is expected to continue to grow in value
and volumes:
§ Coconut water products 149%

§ Coconut flour 115%
§ Coconut milk products 54%
§ Virgin Coconut Oil Products 33%
§ Desiccated coconut 29%
(Source: Uron Salum, Executive Director, APCC at CIDA Workshop July 11-13, 2017)
• With such a growth and demand in the market and the increased market opportunities
the small holders in the Pacific region are embraced with, the EU funded CIDP has
recognised the need to build capacity in the quality, safety and processing of small holder
suppliers in the Pacific in order to sustain market interest, increase market share and
continuing income generation.
• Thus for coconut products that have gained significant markets outlets and shares locally
and internationally must comply to international standards such as Hazard Analysis
Critical Control Point (HACCP) and Good Manufacturing Practices. Consumers are now
more conscious of the need for health and safety food, so it is the responsibility of every
food industry to meet the consumers’ demand. Thus this brings home a tough challenge
for the Pacific business operators to raise up its standard of operation and comply to the
food safety standards HACCP.
Food safety has been a concern to human kind since the dawn of history. Safe Food is a
state in which risk of harm to persons is limited to an acceptable level. The Magnitude of
Food Poisoning is not known as not every incident is recorded and not every incident is
identified.
Food Standards Australia New Zealand (FSANZ) estimated in 2002 that 1.8million New
Zealanders contract food poisoning every year, with the cost exceeding of $1 billion per
annum to the economy. Media released in 2004 indicated that NZ also has one of the
highest rate of food poisoning in the world. In Australia around 5.5 million cases of Food
poisoning are reported every year
Many rules and recommendations advocated in religious text are evidence of the concern
to protect the population against food borne diseases. This concern has grown down the
years and more urgency in the recent decades.
There are many reasons for this which include:

Introduction
1. Foodborne disease remains one of the most widespread public health problem in the
world.
2. Emerging new food pathogens
3. Increase knowledge and awareness of the serious and health effects of food borne
diseases.
4. Advances in the scientific and analytical methods - we now can detect minute
amounts of contaminants in food
5. New food technologies and processing methods – bringing with them new set of
problems
6. Increased international trade in food resulting in increased exposure to food borne
hazards from other areas.
7. Increased contamination of the environment
8. Consumers are more aware of food safety
With the listed concerns of food safety coupled with the lack of enough resources and the
recognition of the limitation of the traditional approaches of food safety there was a need
for a food safety system that was cost effective. HACCP has proven to be such a system.
The HACCP concepts are:

1. A preventative system, not reactive
2. It is a management system tool used to protect the food in the food supply chain
3. It is not a zero-risk system - it is designed to minimise the risk of food safety hazards
4. It is based on three Risk Management Strategies:
a) Identify
b) Assess and
c) Control

Module 1: Introduction to Hazard Analysis Critical
Control Point and Risk Management Strategy
Objectives:
At the end of this module, participants should be able to:
1. Define Hazard Analysis Critical Control Point (HACCP) and Risk Management
Strategy (RMS)
2. Understand the HACCP concept
3. Describe advantages of having HACCP
4. Describe the HACCP system
5. Define Critical Control Point (CCP)
6. Understand the relationship between significant hazards, control measures and
7. CCP’s- Determine Critical Limits for CP
8. Define and explain the purpose of Critical Control Points monitoring
9. Explain the methods and equipment for monitoring critical limits
Risk Management Strategy (RMS) is based on three basic principles
RMS is a Systematic and preventive approach, based on three basic principles which
addresses biological, chemical and physical hazards through anticipation and
prevention, rather than through end-product inspection and testing.
a) The Three Principles of RMS :

• Identify- Identify the risks related to the Issues
• Assess - the risks of those hazards from high to low or the likelihood of the risks being
present and if present its severity to cause harm
• Control – Controlling the Risks by removing, isolating system or protection
b) The three Hazards or Risks are:
• Biological
• Chemical and
• Physical
c) Risk is a combination of the probability that a particular outcome will occur, and the
severity of the harm involved. The risk-based system is used to control the risk factors
that may cause diseases.
Examples: HACCP and Good Agriculture Practices (GAP).

These helps:
• Decrease Food Borne Illnesses

• Provide assurances to customers of food safety
• Can also be a management tool
HACCP or Food Safety Programs

The HACCP concepts:
a) A preventative system, not reactive

b) It is a management system tool used to protect the food in the food supply chain

c) It is not a zero-risk system - it is designed to minimise the risk of food safety hazards
d) It is based on three Risk Management Strategies: Identify, Assess and Control
HACCP
The HACCP system was conceived in the late 1950’s by the Pillbury Company, the
National Aeronautics and Space Administration (NASA) in the USA to ensure safety of
food in the first manned space ship and was introduced to the food industry in the early
1970s.
The system has since then simplified to what it is now - a systematic way of controlling
hazards at the farm and processing level in order to ensure the safety of a product.
The aim of this module is to introduce participants to food safety and the concept of
Hazard Analysis Critical Control Point. (HACCP) which is the main methodology of that is
used in developing risk based food safety programmes. This module will help participants
to understand food safety concepts and its relevance to their food business.
The strength of the system lies in the fact that the HACCP plan:
a) Identifies and analyses the hazards.

b) Identifies the resources required to control them
c) Ensures that these resources are implemented efficiently and effectively.
In essence it is a preventative tool – it helps prevent food-borne illnesses and food related
hazards.

Advantages of HACCP
There are many advantages to be gained by your organisation, your community or

village or to you as the sole owner of your processing unit:
a) HACCP can be applied throughout the food chain, from primary production all the
way to the consumption stage.
b) HACCP offers a systematic approach that addresses all aspects of food safety,
based on scientific evidence.
c) HACCP identifies hazards and focusses on those which are need to be managed to
ensure food safety.
d) HACCP enables compliance with the legal requirements for ensuring managing and
safety quality of products being sold.
e) HACCP helps you/your company, your village business meet customer
requirements.
f) Having a HACCP system in your operation lifts your brand and boosts the confidence
of your trading partners, and international trade.
g) HACCP can be easily integrated into existing quality management systems - it
provides a clear methodology for developing a specific food safety plan.
Description of the HACCP System
HACCP basic principles
HACCP is based on the 7 basic principles:

Principle 1: Conduct a hazard analysis
Principle 2: Identify Critical Control Points (CCP)
Principle 3: Establish critical limit (s)
Principle 4: Establish a CCP monitoring system
Principle 5: Establish corrective actions to be taken when monitoring
indicates that a CCP is not under control
Principle 6: Establish verification procedures for ensuring that the HACCP
system is working as intended
Principle 7: Establish files and maintain records
Figure 1: Principles of HACCP

PROCEDURE – 12 Steps to implement HACCP
1. Assemble HACCP team

2. Describe product
3. Identify intended use
4. Construct flow diagram
5. On-site confirmation of flow diagram
6. List all potential hazards associated with each step, conduct a hazard analysis, and
consider any measures to control identified hazards (Principle 1)
7. Determine Critical Control Points (Principles 2)
8. Establish critical limits for each CCP (Principle 3)
9. Establish a monitoring system for each CCP (Principle 4)
10. Establish corrective actions (Principle 5)
11. Establish verification procedures (Principle 6)
12. Establish Documentation and Record Keeping (Principle 7)
Flowchart for the HACCP system
Flow chart for the HACCP system: On a practical level, the HACCP method is implemented
in a logical sequence based on four points:
a) Hazard analysis
b) Identifying critical control points
c) Managing critical control points
d) Validating the management system

Hazard analysis
PRINCIPLE 1
Establishing CCP
PRINCIPLE 2
Managing CCP
PRINCIPLE 3 PRINCIPLE 4 PRINCIPLE 5
Critical limits Monitoring System Corrective

Actions
Validating the
management
system
PRINCIPLE 6 PRINCIPLE 7
Verification Documentation
Figure 2: Flowchart of the HACCP system

Implementing the HACCP method
Apply using 12 step strategy that is divided into two phases

Preparatory Phase: Planning
Step 1: Set up HACCP Team
Step 2: Describe the characteristics of the product
Step 3: Identifying the intended use of the product
Step 4: Construct the flow diagram
Step 5: Confirm the flow diagram on site

Implementation Phase: Apply 7 principles
Step 6: Identify and analyse all potential hazards associated with each step
of the process and establish one or more control measures
Step 7: Identify critical control points (CCP)
Step 8: Establish critical limits for each CCP
Step 9: Establish a CCP monitoring system
Step 10: Establish a corrective action plan
Step 11: Establish verification and review procedures
Step 12: Establish a documentation and record-keeping system
Figure 3: HACCP Application
To meet the requirements of the Food Safety Standard, the food safety program must
include:
a) documented control measures

b) nominated supervision and monitoring
c) assessment for effectiveness
d) corrective action
e) records

The Preparatory phase:
1. Step 1: Setting up the HACCP Team
a) It must be a multidisciplinary team

b) Team members must have experience and knowledge of the products, processes
and hazards
c) An external expert may be used.
2. Step 2: Describing the product characteristics
The description must be given in order to help identify the factors that may affect the safety
and quality of the products and include:
a) Description of the raw materials

b) Product data sheet
c) Chemical, physical and biological; characteristics
d) Origin
e) Delivery method,
f) type of packaging,
g) storage conditions.
h) Abuse potential of the product
3. Step 3: Identifying the intended us of the product
The potential users or consumers of the product should be identified, and any groups
recognized as vulnerable should be indicated. Any forecast deviation from normal usage
should also be considered.

4. Step 4: Constructing the flow diagram
The purpose of this step is to provide a comprehensive and concise description of the
different stages of the process.
This involves creating a detailed schematic representation of all steps to be followed during
the production process.
The following is an example of a basic process flow diagram to start from:
1
• Receving
2
• Processing
3
• Packing
4
• Storage
5
• Transport & Distribution
Figure 5: Basic HACCP Flowchart

It should give a summary of the main stages of the production, from receiving of the raw
materials, processing steps right up to the shipping or sending the finished products to
intended locations.
This flow diagram is then used to identify the Hazards at each step in the process.
5. Step 5: On-site verification/conformation of the flow diagram
On-site verification will ensure that the flow diagram to be used to perform hazard analyses
is a true reflection of the production process concerned.
Implementation phase
This step involves the application of the 7 principles of HACCP.
6. Step 6: Conduct a hazard analysis (Principle 1)
Involves three steps:
a) identify hazards (chemical, biological or physical) at the different stages of the

process,
b) determining the likelihood of the hazards occurring
c) identifying control measures to be implemented to manage food quality and safety

Hazard Matrix
The assessment of the significance of Food Safety & Quality hazards uses the following
matrix of the severity (consequences) and the likelihood (frequency). A value of 1-10
indicates a significant Food Safety or Quality Issue (i.e. above the line), which signifies that
control measure(s) must be put in place – CCP or QCP status control measures & that
monitoring & records must be kept. The CCP decision tree should be used to determine
CCP’s. Food Safety & Quality issues that are not significant will have values of 11 – 25. It
is up to the HACCP team members to determine whether it makes good sense to have any
control measures in place (i.e. CP or QP status control measures).
FOOD SAFETY HAZARD QUALITY HAZARDS

HAZARD SEVERITY: QUALITY SEVERITY
1. Death occurs 1. Business ceases trading immediately

2. Serious illness occurs 2. Product recall due to poor quality
3. Product recall 3. Delivery rejected by the customer
4. Customer complaint 4. Non-significant warning from customer
5. Not significant 5. Not of commercial significance
HAZARD LIKELIHOOD QUALITY LIKELIHOOD
A. Happens a lot at our business A. Happens often at our place

B. Has happened at someone else’s business B. Has happened at our place
C. Could occur C. Has happened at someone else’s place
D. Not expected to occur D. Not expected to occur
E. Practically impossible E. Practically impossible
LIKELIHOOD
SEVERITY A B C D E
1 1 2 4 7 11
2 3 5 8 12 16
3 6 9 13 17 20
4 10 14 18 21 23
5 15 19 22 24 25
Figure 6: HACCP Risk Matrix

CCP Decision Tree
The CCP decision Tree is used to confirm that any significant Hazard is in fact a true CCP.
By answering the 4 questions and using scientific knowledge and understanding of the
process being assessed this Decision Tree will confirm all CCP’s
Q1 Do preventative control measures

exist?
Yes No Modify step, process or

product
Is control at this step Yes

necessary for safety?
No Not a CCP STOP*
Q2 Is the step specifically designed to

eliminate or reduce the likely Yes
occurrence of a hazard to an
acceptable level? **
No
Q3 Could contamination with identified

hazard(s) occur in excess of
acceptable level(s) or could these
increase to unacceptable levels? **
Yes No Not a CCP
STOP*
Q4 Will a subsequent step eliminate

identified hazard(s) or reduce likely
occurrence to acceptable level(s)? **
CRITICAL
Yes No
CONTROL POINT
(CCP)
Not a CCP STOP*
* Proceed to the next identified hazard in the described process
** Acceptable and unacceptable levels need to be determined with the

overall objectives in identifying the CCPs of the HACCP plan
Figure 7: CCP Decision Tree

7. Step 7: Identify critical control point (CCP)(Principle 2)
This step involves determining which of the hazards identified in Step 6 is critical to
safeguarding the hygiene and safety of the product. The Codex Alimentarius can be used.
8. Step 8: Establish critical limit of each CCP (Principle 3)
Critical limits for each CPP must now be identified.

The limits can be a numeral value, sensory parameter or measurement.
To also note that a single CCP can have several critical limits.
9. Step 9: Establish a system to monitor control of CCPs (Principle 4)
This involves conducting analyses or taking measurements, recording observations or

saving data to ensure that the CCPs are being controlled.
The procedures followed must be able to detect any loss of control.
10. Step 10: Establish a corrective action to be taken when monitoring indicates
that a CCP is not under control (Principle 5)
Corrective actions for each CCP to be developed to address any deviation.

This involves the immediate actions that the operator responsible for the step in the process
must implement in order to meet the control requirements of their processes.
The actions must ensure that the CCP has been brought under control and provide for the
management of the affected product.
11. Step 11: Apply verification procedures to confirm that the HACCP system is
working effectively (Principle 6)
This step involves verifying the effectiveness of the system and its effective implementation.
Use of verification and auditing methods, procedures and tests, random sampling and
analysis to determine whether the system is working.
12. Step 12: Establish a documentation and record-keeping system (Principle 7)
Establish a documentation system which considers the various documents, procedures,

operating modes and records.

Critical Control Point (CCP)
A critical control point is a step at which control can be applied to prevent, eliminate a food
safety hazard or reduce it to an acceptable level. If it is not undertaken, then there is a high
probability that the hazards will enter the food. Not all control measures are CCPs - it is
determined from the significance of the hazard - each significant hazard must have at least
one CCP status control measure.
If the absence of a control measure means that there is a high likelihood that product is
unsafe, then this control measure is a CCP.
CCP can be steps where hazards can be:
a) Prevented
b) Eliminated
c) Reduced to acceptable levels
CCP placement must be at the processing step or steps that adequately control the
significant hazard.
CCP are product and process specific and are impacted by:
a) Layout of the plant or processing line

b) Finished product formulation
c) Sequence of processing steps
d) Ingredients
e) Sanitation or other support programs
The CCP must be adhered for consumer safety and any failure at the CCP has a direct
impact on food safety in a coconut processing situation.
CCP’s must have the following key attributes;
CCP Key Attribute Example
1 Must manage or control a significant Food poisoning due to growth of
hazard pathogenic bacteria
2 Controls must be specific Measure temperature of Coldroom or
product
3 CCP’s must be measurable Temperature in °C
4 Critical Limits must be set CL - < 5 °C
5 CCP’s must be able to be measured in Operator or storeman can measure
real time by staff completing tasks temperature
6 Corrective Actions must be completed Close doors, - repair faulty refrigeration
if CCP is found to be outside CL equipment
7 Records must be kept Record Temperatures 2 times per day
8 Staff must be trained in all CCP’s
QCP’s can also follow these key attributes

The Control Point (CPs)
The control point (CP) “makes good sense to do” status control measures. Failure at a CP
does not necessarily have a direct impact on food safety and failure normally only requires
a process adjustment.
Establishing Critical Limits
Critical Limit
The Critical limit is a maximum and/or minimum value to which a biological, chemical or
physical parameter must be controlled at CCP to prevent, eliminate or reduce the
occurrence of a food safety hazard to an acceptable level.
Example of CL for species related hazard
An example is the Pasteurisation process with raw milk as the product.
The Process of pasteurization involves the heating of raw milk at 72 °C or a very short time
i.e.15 seconds and then chilling it down quickly. The process is designed to kill pathogens
which are harmful to human being.
The Hazard Analysis looks at what can go wrong? i.e. The pathogens may survive the
pasteurisation process.
CCP or Critical Control Point: Is the heating element or the Cooker
CL or Critical Limit: no pathogen detected
Table 1: Example of CL for process related hazards
Example: Coconut Drying

Product: Copra
Hazard: Mould growth due to high moisture
CCP: Moisture content lowered by Drier
Critical Limit: < 7% Moisture to prevent mould growth
Monitoring Measure moisture at end of each drying batch
Records Monitor and record moisture results for each batch
Corrective Action Continue drying until correct moisture is achieved

Critical Control Point Monitoring
Monitoring
Monitoring is a planned sequence of observations or measurements to assess whether a

CCP is under control and to produce an accurate record to demonstrate that critical limits
have been met.
Purpose of Monitoring
a) To ensure that a critical limit is meant

b) To provide documentation that critical limits have been met
c) To identify when there is a loss of control (a deviation occurs at a CCP)
Elements of monitoring
Determine:
a) What will be monitored - a measurement or measurement to assess if the CCP

is operating within the CL.
b) How monitoring will be performed - measurements (quantitative CL) or
observations (qualitative CL) and needs to be real time and accurate.
c) The frequency of monitoring - it should be sufficient to ensure that the CL is met
and can be non-continuous or continuous.
d) Who will conduct the monitoring - Personnel that have trained to perform a
specific monitoring activity or a continuous monitoring device.
e) Staff must fully understand the importance of CCP monitoring, have ready access
to the monitoring activity, accurately report each monitoring activity and must
immediately report any deviations?
Examples of monitoring
These could include:

a) Time and temperature of d) volume
process e) formulations
b) pH f) dilutions
c) weights and measurements g) cleanliness
Examples of monitoring equipment

These could include:
a) Thermometers and Thermostat e) Data loggers
b) Record charts f) Metal detectors
c) Clocks g) Refractometers
d) pH meters h) Scales

Prerequisite programs (PRP)
The HACCP System is not a stand-alone program it can only work effectively with the
prerequisite program (PRP) in place. The PRP is a support system that has a set of
guidelines and procedures which is to be followed to ensure food produced is free from any
contamination and is safe for consumption.
Figure 8: The Complete HACCP Process

Pre Requisite Programs (PRP) or Good Manufacturing Practices (GMP) is the combination
of manufacturing and management practices aimed at ensuring food products are
consistently produced to meet specifications and customers’ expectations.
It is the support programs or activities that must be in place so that the HACCP plan can be
implemented effectively.
These programs can include but are not limited to the following:
PRP’s can be created by companies to control any Hazards that exist in the business
including Food Safety Hazards (not CCP’s) Quality Hazards, Managing Suppliers and
ingredients, Worker Safety Hazards, Quality Hazards, Food Fraud or Food defence
hazards, Management systems such as stock control and traceability and other systems
such as GAP (Good Agricultural Practices), Organic Kosher etc.
Each facility and business needs to determine what PRP’s are required and include any
necessary PRP’s in the HACCP System

More information regarding PRP’s is contained in Module 6.
• PRP - Approved Suppliers

• PRP - SITE Standard: Building, Infrastructure and Premises
• PRP - Transportation Receiving and Storage
• PRP - Equipment Maintenance
• PRP - Calibration
• PRP - GMP or GHP (Good Manufacturing Practice or Good Handling Practice)
• PRP - GAP (Good Agricultural Practices)
• PRP - Personal Hygiene
• PRP - Staff Training
• PRP - Cleaning and Sanitation
• PRP - Chemical Control
• PRP - Documents Control
• PRP - Pest Control
• PRP- Traceability and Recall systems
• PRP - Mock Recall
• PRP - Allergen Control
• PRP - Visitors Policy
• PRP - Food Defence and Food Fraud (VACCP & TACCP)
• PRP - Verification
• PRP - Auditing
• PRP - Corrective Actions & Complaints
• PRP - Organic Systems

Module 2: Hazards
Objectives
1. Understand the meaning of Hazards

2. What the hazards are
3. The three types of Hazards
4. Identify significant hazards
5. Identify Control Measure
.1 Definition of Hazard
A hazard is any biological, chemical or physical agents that is reasonably likely to cause
illnesses or injury in the absence of control (s)
.2 Why hazard analysis is conducted?
To identify:
a) All potential food safety hazards

b) Which hazards are significant
c) Measures to control the significant hazard
.3 Types of Hazards:

Module 2: Hazards
Physical Hazards
These are foreign objects that are capable of injuring consumers.

Includes soil particles, metal, glass, word, hard plastic; insects, sand insect parts.
Chemical Hazards
If not controlled will cause illness.

Includes natural toxins (aflatoxins), pesticides, sanitizers, allergens, undeclared ingredients,
cross contaminants and unapproved additives
Biological Hazards
If not controlled will cause illness.

Includes disease causing bacteria (Salmonella spp., Escherichia coli, Staphylococcus
aureus, Clostridium botulinum, Shigella) viruses (hepatitis A).
.4 The Five Steps in a Hazard Analysis
• List process steps

• Identify potential food safety hazards
• Assess its likelihood to cause serious harm from high to low
• Determine if the hazard is significant
• Justify the decision
.5 Control measures
Biological Hazards may include the following:
a) Time/temperature controls
b) Heating and cooking
c) Freezing
d) Fermentation/pH controls
e) Drying
f) Salt or other preservations
g) Cooking
h) Proper sanitation
Chemical Hazards may include the following

a) Source controls
b) Time/temperature controls
c) Production controls
d) Labelling controls
Physical Hazards may include the following:
a) Source control
b) Production control

Module 3: Coconut Products
Objectives
1. Identify the different the different coconut products

2. Identify ways coconut of developing other coconut products
3. Describe the different characteristics of various coconut products and uses
4. Describe how the different coconut products are made.
COCONUT OIL
Description
Coconut oil is extracted from the meat of the coconut. Coconut oil is an edible oil
which is made from the meat or kernel of mature coconuts. There are two main
processes for extraction of the oil: dry and wet.
Uses
Coconut oil has several different applications, although its primary use is for cooking. It is
often touted as being a “miracle oil” compared to some of its other cooking alternatives. This
is because, even though it contains 90% saturated fat and only around 9%
monounsaturated and polyunsaturated fats, coconut oil is mostly made from medium chain
fatty acids, making it a healthier choice. At the same time, the high saturated fat content
ensures that the oil lasts for a long time and is also very heat-stable. This means that it is
unlikely to degrade into trans fats when you cook with it.
Preparation
The dry method.
This is the classic technique, which involves using fire or sunlight to dry coconut meat
extracted from the shell, resulting in what is known as copra. This copra can then be pressed
in order to squeeze out the oil, or dissolved with solvents. Either way, the result is coconut
oil plus mash rich in fibre and protein. Although simple and straightforward, the dry process
does lose oil along the way.
The wet process method
This method uses the raw coconut instead of the dried copra, but it has to deal with the
problem of separating the oil and the water inside the coconut, which are mixed together
through emulsion. Original wet process techniques involved boiling the coconuts, but this
resulted in a lot of wasted materials and discoloured oil.
Modern methods
This method relies on rely centrifuges in order to separate the two substances, along with
pre-treatments that use acids, salts, or heat. Despite their relative versatility and

sophistication, wet processes are still not as efficient as dry ones due to a lower yield and
the higher amounts of energy and time involve.
COCONUT BUTTER
Description
Coconut butter is made by blending the dried coconut meat. Coconut butter makes
use of the meat of the coconut in order to achieve a thick, solid paste that has a
similar texture to other traditional butters and is frequently used in cooking.
There are several straightforward ways to make coconut butter, all using shredded
and dried coconut, but the easiest one is simply to blend it. This can be done with a
high-powered blender or a food processor. If the result does not have the consistency
of butter, some coconut oil can be added to the mixture (see the recipe below).
Uses
Coconut butter is used almost exclusively in cooking.
Preparation
a) Add 4-5 cups of dried coconut to your food processor. It can be either shredded or
flaked, but it must be unsweetened.
b) Run the food processor for at least 15 minutes. You will notice the texture of the
coconut butter changing during this process, as it gradually turns into a thick,
viscous liquid. You will need to periodically scrape pieces of coconut down from the
sides of the food processor.
c) If you are not getting right consistency, add a little coconut oil. Note that it should
remain slightly runny while it is in the food processor.
d) Pour out the butter into a glass jar, cover, and store at room temperature. You will
notice that it begins to solidify and harden.

DESICCATED/SHREDDED/FLAKED COCONUT
Description
Flaked coconut comes in small, flat pieces of dried coconut. There is very little
difference between flaked, shredded and desiccated coconut, so many people use
them interchangeably. They are all made from the meat of the coconut, which is
ground or put through a grater. The biggest difference between the three of them is
the shape. Shredded coconut comes in long, thin strips; flaked coconut comes in
smaller, flatter pieces; and desiccated coconut is even finer and obtained through
grinding.
Uses
All three varieties are used in cooking, primarily for desserts. Although they are
sometimes included in the recipe itself, most of the times the coconut is used as a
topping sprinkled over the dish. Shredded coconut can also be used to make your
own coconut milk. These different types of coconut can be found at many
supermarkets and groceries, particularly ethnic ones.
Preparation
a) The meat of the coconut needs to be dried beforehand.

b) Then it is simply a matter of grating or grinding the coconut until you achieve the
proper consistency.
c) The end product can be stored in a dry place and kept there for up to six months, as
long as it is packaged carefully.

COCONUT FLOUR
Preparation
Coconut flour is made using the solid remnants left over after making coconut milk
Coconut flour is made from the solid remnants left over after making coconut milk.
After a while, these solids turn to flakes and, if they are baked and then blended, the
result is a white, powdery substance that is used as flour.
Uses
Coconut flour is often used for cooking and represents an excellent alternative for
people who do not want to consume grains or who are allergic to gluten. Others
simply prefer the taste of food prepared using this flour. The sensation of eating a
cake or bread prepared with coconut flour is quite different from other flours due to
its very high fibre content. Baked goods are typically heavier, denser and much more
satiating. Many people prefer it because it does not contain any gluten or grains,
making it an ideal for those with digestive problems, gluten intolerance, or leaky gut.
It is also rich in fibre and protein. Lastly, coconut flour is typically sweeter than other
types of flour, so baked goods that use it require less sweetening.
Preparation
a) The pulp left over after making coconut milk should be spread out over a baking sheet
and placed in the oven at 200 degrees Fahrenheit until it is completely dried.
b) Afterwards it should be processed in a blender or food processor until it turns into a
fine powder and is ready to be used as coconut flour.
c) The flour can be stored in a dry area for several months.

COCONUT MILK
Description
Coconut milk is traditionally obtained by grating coconut meat and squeezing it

through cheesecloth. Coconut milk should not be confused with coconut water, as
they are two completely different things. For starters, coconut water is clear and
coconut milk is white. They are also obtained in different ways. While coconut water
is simply the liquid found in the interior of the coconut, the milk is made by grating
the meat of a brown coconut. Due to the high oil content of the coconut meat, the
result is coconut milk full of saturated fats and rich in taste and colour.
Uses
It is an important ingredient in many different cuisines, particularly Asian (see this

grilled chicken with bok choy recipe). The thinner milk is typically used in most dishes,
while the thicker, fattier coconut milk is normally reserved for sauces and desserts
(try this Candida-safe coconut ice cream). Occasionally, coconut milk is also used
as a drink (see this coconut smoothie). On its own, it tastes somewhat like cow’s milk
and it is often served diluted with water. More commonly, though, coconut milk is
mixed with other ingredients in order to obtain various popular drinks such as Pina
Colada. One unusual use for coconut milk is in horticulture.
Preparation.
a) Various preparation methods allow for coconut milk of varying fat percentages, ranging
anywhere from 22% to 5% fat.
b) High-fat coconut milk is traditionally obtained by grating coconut meat and squeezing
it through cheesecloth. In order to decrease the fat percentage, the coconut meat is
left to soak in warm water and then the process is repeated two or three times.
c) It is also possible to make your own coconut milk at home.
d) It was discovered that the milk can promote plant growth due to its content of
cytokinin’s.
e) Although it does not work for all types of plants, some grains such as wheat have
yielded significant improvements by adding 10% coconut milk to its substrate.
e)

COCONUT WATER
Description
Coconut water is the liquid found inside coconuts and, although high in natural
sugars, is highly regarded for its rich nutritional value. This natural juice is packed
with minerals such as iron, calcium and magnesium, multiple B-complex vitamins,
bioactive enzymes, electrolytes, and cytokinin’s.
Uses
Coconut water works very well in treating dehydration, and particularly the fluid loss
resulting from gastrointestinal issues such as diarrhoea. Because of its special
composition, it is regarded as being more effective than any kind of soft drink for this
purpose. Coconut water is not only tasty, but it is perfectly safe for all people including
infants and pregnant women.
Preparation
a) The slightly immature coconuts (between 5 and 7 months of age) that are harvested
for this purpose.
b) Younger coconuts have water which is bitter and not yet rich in nutrients, while older
coconuts do not have as much water as immature ones.
c) If harvested at the most opportune time, a coconut can have as much as one litre of
water inside it.
d) Coconut water can also be found separately either bottled or packaged, although it
is not generally as nutritious since it includes additives that prolong its shelf life.
e) Once opened, the water in coconuts should be consumed immediately otherwise it
starts to turn sour. It can last for a few days if it is stored in the fridge.
f) Typically, the most common method is to use a sharp tool such as a sickle in order
to chisel out the shell at one end of the coconut and then cut into the hard layer.
g) The coconut water can be sipped directly from the coconut with a straw, although
some people prefer to add other ingredients such as mint leaves or lemon slices.

COCONUT SUGAR
Description
Coconut sugar is a sugar that is obtained from the coconut palm tree. Coconut sugar
is a type of sugar that is obtained from the coconut palm tree, differentiating itself
from most other coconut products that are made using the fruit itself. That is why in
certain areas it is referred to as coconut palm sugar in order to avoid confusion. It is
a natural sweetener that has become more and more popular in recent years.
Uses
It is used in cooking or in any other areas where people would prefer an alternative
to refined sugars. Research is still ongoing regarding the merits of coconut sugar,
but it appears to have more nutrients and a lower glycemic index than refined sugar
so it is considered to be a superior sweetener.
Preparations
a) Coconut sugar is obtained by collecting liquid sap from the coconut palm tree, then
leaving the sap to dry in the heat.
b) After most of the water has evaporated, the resulting product can be ground and
used as sugar.
c) As the popularity of coconut sugar has increased it has become more readily
available. Many natural food markets stock it and it can also be found online.
d) Although the process of making it is simple, it does require access to palm tree sap,
which is not easy to come by.
COCONUT NECTAR
Description
Coconut nectar is made from the sap of coconut blossoms. Like coconut sugar,
coconut nectar is another natural sweetener provided by this plant, except that this
one is in liquid form and it is made from the sap of coconut blossoms. It is rich in
minerals and vitamins and also has a lower glycaemic index than most sweeteners.
Uses
Coconut nectar is often used in cooking as an alternative to agave nectar. It has

around 10% fructose, which is far lower than the 50% to 90% which is commonly
found in agave nectar.
Preparation
It is made through a simple and natural process that involves collecting sap from
coconut blossoms and boiling it. Initially, the sap is dry and thick, but it reaches a far
more liquid state at the end of the process.

COCONUT AMINOS
Description
Coconut amino is made from the sap of the coconut palm tree. Coconut amino is an
amino acid liquid that is often used as a substitute for soy sauce, even though it does
not contain any soy. This remarkable liquid is made from the sap of the coconut palm
tree. Coconut amino has a lot of applications in cooking, basically in any recipe
where you might use soy sauce.
Uses
It can therefore be used in many Chinese and vegan recipes, but it is also employed
for sauces and for salad dressings. From a nutritional standpoint, coconut amino is
far more potent than traditional soy sauce due to the significantly increased quantities
of amino acids. If you are concerned about the use of GMO soy in your soy sauce,
coconut amino is an excellent alternative, and is suitable for a Candida diet. Coconut
amino is found in many natural food markets and is also available online. However,
the flavour of the product can vary significantly from one brand to another based on
the type of salt that they use.
Preparation
In order to make the coconut amino, the sap is mixed with a sea salt rich in minerals.
This creates a product that is close in texture and taste to soy sauce.
COCONUT VINEGAR
Description
Coconut vinegar is made either from coconut water or from the sap of the coconut
palm tree Coconut vinegar is made either from coconut water or from the sap of
the coconut palm tree Coconut vinegar is a condiment that is similar to other types
of vinegars obtained through fermentation. It has a white color and a very pungent
and acidic taste, and it is the preferred type of vinegar used in several Asian cuisines.
It is a better choice than regular white vinegar if you’re on a Candida diet, but not as
suitable as apple cider vinegar.
Uses
Coconut vinegar is used in cooking and it is a preferred condiment in many cuisines.

It also contains plenty of minerals and amino acids. For people looking to use it in
their recipes, it can be used as a substitute in most recipes that normally call for
vinegar.
Preparation
Coconut vinegar is made either from coconut water or from the sap of the coconut
palm tree. This is boiled in water and yeast is added, giving it a distinct taste
compared to other vinegars. It is then set aside for various lengths of time depending
on the desired acidity level.

Module 4: GMP (Good Manufacturing Practice)
“Good Manufacturing Practices or GMP is the combination of manufacturing and
management practices aimed at ensuring food products are consistently produced to meet
specifications and customer expectations” NZFST 1999
Objectives
1. Understand the key concepts of good manufacturing.

2. Understand specific requirements on quality management.
3. Develop actions to resolve your current problems.
What is GMP
GMP is a set of guidelines and procedures that have to be followed to ensure that the food
products manufactured in a particular plant are free from the presence of dirt, contaminants
and pathogenic micro-organisms.
Following GMP guidelines ensures the prevention of food adulteration and contaminant that
arise from unsanitary conditions.
Advantages of having GMP
GMP Is a support system for HACCP and if properly in place and adhered to, the HACCP
plan will be successful.
To meet the requirements of the Food Safety Standard, the food safety
program must include:
a) documented control measures

b) nominated supervision and monitoring
c) assessment for effectiveness
d) corrective action
e) Records
Why are they necessary?
a) meet regulatory requirements

b) to demonstrate safe food controls
c) statement of commitment to produce safe food
d) evidence of reasonable precautions taken
e) basis for auditing process
f) training aid for staff
g) Provide a high level of confidence in food businesses ability to produce safe food.

Module 4: GMP
Food business responsible for
a) identifying hazards
b) putting in place controls
Principles of GMP
There are three key issues:
1. Food Safety Program is the “say what you do”

2. Implementation is the “do what you say”
3. Record keeping, and auditing is the “prove it”
Personnel hygiene
It is to do with the total personal cleanliness of operators or workers, all those involved with
the preparation of the product from the start to the finish.
The clean body includes: showered, tooth brushed, hair and moustache and beard cleaned
and trimmed short and covered, clean uniform, or working clothes, foot ware is appropriate
and cleaned, finger nails trimmed and clean, hands clean, no boils or scabies or skin
diseases etc.
Skin diseases must be treated and well covered with appropriated dressing etc.
Requirements
All personnel working in direct contact with products shall conform to hygienic practices
while on duty to the extent necessary to protect the product against contamination. The
methods for maintaining cleanliness include, but are not limited to:
a) Wearing outer garments suitable to the operation in a manner that

protects against the contamination.
b) Maintaining adequate personal cleanliness.
c) Washing hands thoroughly (and sanitizing if necessary, to protect against
contamination with undesirable microorganisms)
d) Maintaining gloves, if they are used in product handling, in an intact, clean,
and sanitary condition.
e) Wearing, where appropriate, in an effective manner, hair cap, beard
covers, or other effective hair restraints.
Good Personal Hygiene
Includes the following
a) Regular bathing everyday

b) brushing teeth
c) washing hands - before entering the production area, after visiting the toilet, after
eating, after smoking
d) Wearing clean clothes daily

Module 5: Cleaning & Sanitation
Objectives
At the end of this module, participants should be able to better understand:
1. The importance of Cleaning and Sanitation in any coconut processing activities

and
2. How it contributes towards the elimination of hazards in the plant, in the
processing line and ultimately from the products.
Scope
Cleaning and sanitation is part of the Good Manufacturing practices an should be practiced
to avoid contamination of personnel and during manufacturing of products.
It should cover all aspects of manufacturing:
a) Personnel
b) Premises
c) Equipment and apparatus
d) Production materials and containers
e) Products for cleaning and sanitation
f) All potential sources of contamination
Basic cleaning principles & practices
Cleaning and sanitation is a key consideration when designing premises and equipment to
operate in a cosmetic industry.
Proper cleaning plays an important role.
Cleaning Methods
The methods used to establish a clean manufacturing environment vary from company to
company. The goal is always the same, to acquire the level of cleanliness to maintain a high
product quality while minimizing costs.
To understand the concept of cleanliness, it is necessary to define some common words
used in the industry. Most important are the words clean, sanitation, hygiene, and sterile.
Cleaning operations shall be performed in a manner to prevent contamination of materials
and products. Cleaning practices can be divided by:
a) “deep cleaning”,
b) “housekeeping cleaning”, and
c) “Maintenance cleaning”.

Required cleaning chemicals and Equipment
For proper cleaning in a coconut processing factory the requirements are:
a) Chemical compound
b) Sanitisers
c) Good scrubbing brushes
d) Mop
e) And good strong arm with muscles
f) Buckets and measuring cylinder or scales
Importance of using Hot water and cleaning compounds
The use of hot water and cleaning compounds will help lift out and remove grease and oils
from the equipment and tables and floor.
Storage of cleaning materials
a) All cleaning chemicals shall be properly labelled and stored in a locked

compartment, away from production and storage areas.
b) Cleaning equipment and tools shall be supplied and be readily available for
use.
c) All cleaning equipment shall be maintained and stored in such a way as not to
contaminate product or equipment.
Benefits of Proper cleaning
For personnel
To prevent contamination risk that effect personnel health
For product
To prevent contamination of the products
To maintain the high standard of product quality
For company
To save on cost, avoid reworks and rejects
To avoid consumer complaints
To avoid potential product recall
For consumers
To get safe and good quality product

Sanitation of premises
In any coconut processing plant, there is always the problem of waste after processing.
These are:
a) piles of husks
b) used coconut shells
c) waste grated coconuts
d) waste coconut water
These wastes if not properly or immediately removed daily will attract insects and flies as
well rodents. The coconut water if not disposed of properly will corrode concrete pavements
and drains resulting in a rancid or putrid smell.
So, it is important that after each day processing all waste must be disposed of and working
area outside are washed thoroughly with chemical agents and then sanitised overnight.
Sanitation of equipment
The equipment used for coconut processing will always end up oily and greasy because of
the nature of the product. If it is not cleaned thoroughly it can be a source of contamination.
Requirements are:
• Hot water
• Chemical agent for general cleaning
• Sanitisers
• And good scrubbing brushes
• Strong arms etc.
• Some systems are cleaned using CIP – Clean in place
Cleaning Procedure
The equipment is to be washed down first with warm water to remove all the solids before
proper cleaning. Then the chemical mix with warm water is applied with scrubbing brushes
through and through and all over the machine until the equipment is clean - i.e. no more oily
or greasy. Hot water to be poured over to ensure all oils or grease is removed. Then apply
the sanitiser solution on the equipment and this can be left overnight until the next
production activities.
Before any production is carried out, a thorough rinse of the equipment is needed to remove
the sanitiser. This will ensure that there will be no chemical residues on the equipment
during the processing.

Key Steps in Cleaning
Correct cleaning equipment

•Correct detergents for each cleaning task.
1. Preparation •Correct training and systems
•SAFETY, Glasses, gloves etc
Remove all rubbish & packaging before starting to clean

•Make machinery safe for cleaning
•Disconnect power or air if required
2. Dismantle •Dismantle equipment
•Do not put parts on dirty floor, use tables etc.
DRY CLEAN
•Scape or wipe off major food residue from equipment and floors
•Remove rubbish
3. Preclean
•Rinse equipment with water
Use Hot water with detergent

•Ensure detergents strengths are correct – (Follow Cleaning charts)
•Use correct cleaning equipment in good order (No shaggy dog brushes or scotch brites)
4. Wash •Use mechanical action (SCRUBBING) to remove food soil
•WATCH FOR DIRTY SPOTS
Ensure detergents or foam are left on the surface long enough to do their job
•Use clean water to remove food soil and detergent
•Inspect clean surfaces look for dirty spots
5. Rinse •Rewash if necessary (Step 2)
•Rinse cleaning equipment also (Brushes, buckets, scourers).
Use a sanitiser to kill any remaining germs or bacteria on equipment surfaces

•Ensure correct strengths are used
•Too weak – will not kill bacteria
6. Sanitise •Too Strong – will contaminate products or corrode equipment
•Ensure correct contact times are maintained.
Ensure no product residues are present

•Always follow instructions
7. Final Rinse •INSPECT TO ENSURE ALL EQUIPMENT IS CORRECTLY CLEANED.
Allow equipment to drain and dry

•Store in correct place
•Ensure equipment is not on floor
10. Inspect •Ensure equipment will be ready for use
Dry & Store
•Ensure equipment will not get contaminated during storage.
Figure 9: The Complete HACCP Process

Documentation and cleaning instructions
a) Procedures: All cleaning procedures must be documented for the workers to follow.
This will include the How to wash the premises, equipment, the floor, the walls, the
ceilings, the drains etc.
b) All chemicals to be used must be identified and formulations of mix must be clearly
written for those that responsible.
c) The use of hot water is a must for this oily product to ensure all oils is removed.
Monitoring
Monitoring of cleaning is important to ensure the people responsible are doing the
right things by the supervisor and if there is an error in chemical mix or procedure
there needs to be corrected
Ensure that all cleaning is inspected and checked for adequacy
Corrective action
Inspect to check cleaning is correct.

Dirty or poorly cleaned items need to be recleaned by following all necessary steps.
For any errors or ineffective cleaning results, training must be carried out on staff
responsible.
Records
A cleaning matrix must be developed to identify the equipment that are to be cleaned
daily, those that need to be cleaned weekly or monthly or quarterly etc. All cleaning
activities must be recorded and the people responsible to sign of every record and
verified by the supervisor in place. These records show the evidence of what has
been done.
Regular GMP audits or inspections should also be used to confirm cleaning
standards are being maintained

Module 6 PRP’s Prerequisite or Support Systems
Objectives
1. Understand Pre -Requisite Program

2. Its importance and
3. How to comply
HACCP focusses on “on -line” activities and it cannot work alone but need support system
to function effectively before any production can commence. Thus, the term Pre-Requisite
Programs. The PRP is a support system that has a set of guidelines and procedures
which is to be followed to ensure food produced is free from any contamination and is safe
for consumption.
With the Pre-Requisite programs, three main areas that should comply to standards are
a) appropriate premises
b) facilities and
c) equipment is vital
Premises: The site selection of the factory is important must be accessible to roads /
transport and water and power supply. Area must be well drained and be well away from
any pollution activity. It would be ideal to be near the supply of raw materials. The premises
must always be kept tidy and clean.
Facilities: A good building of concrete infrastructure with linear walls and ceilings is
appropriate with good ventilation, proper drainage system and good gradient flooring for
ease of water flow. The process system must be linear and moving forward right through
from the start to the end of production for ease of movement.
Equipment: All processing equipment are ideally required to be stainless steel for ease
of cleaning and durability. The use of timber and wood is inappropriate as it would contribute
towards insect infestation, moulding and bacterial growth.

Examples of PRPs or Support systems for the Food safety program are
listed below:
PRP - Approved Supplier Program
Document Procedure
The purpose of the Approved Supplier Programme is to ensure that the business purchases
materials and services to ensure the best possible outcomes to meet quality criteria and
customer satisfaction. This procedure will cover who’s responsible, scope, detailed
procedure of the approved supplier programme, monitoring of approved suppliers and
records. The Approved Supplier programme provides a system of controls and vendor
expectations, which when strictly adhered to, will provide a high degree of Food Safety and
Quality Assurance for all materials purchased by the operation.
Monitoring procedure
Suppliers are to be trained on quality and safety measures in regard to products and need
to be checked now and then on Good Agriculture Practices. Products supplied can be tested
to ensure safety measures have been followed.
A supplier list to be maintained by facility
Corrective action
In case the suppliers do not adhere to the rules they can either be removed from supplying
or a letter of warning can be issued
Records
A record of inspection and audit activities and corrective action at farm level or business
level reports must be kept for future actions.
Identify the difference between Food Quality and Food Safety
1. Approved Supply Program focusses on what matters to the customers. And this will
vary depending on the types of products and customers. It is important to know your
suppliers, what they produce, where and how.
2. It is important that they are a registered business and have a registered premise and
that they produce the best produce for you.
3. The food safety program, HACCP is important to be applied at source of supply
whether at the farm or at a factory where packaging or ingredient may be produced
4. It is vital for your supplier to comply with safety practices or hygienic standards when
producing your produce or ingredients or packaging materials.
5. Any elimination of hazards at farm or factory level and through distribution will
contribute towards the safety of the product.
6. A record of suppliers and their contact details and the list of the gods they supplied
must be kept by the company. Develop a matrix of suppliers, including the name of
the producer or company and what they supply.
7. It is important to record their contact addresses for the purposes of ordering. It is
also important to have a record of what they supplied and the date for traceability.
8. It is good to build a good relationship with them.

PRP - SITE Standard: Building, Infrastructure and Premises
Because coconut or VCO is considered as a functional food, the factory for processing must
comply with conditions required for food processing factories. The location of the factory,
the design and the building structure and construction, the operation and maintenance
including the environmental surroundings and the elements in the building are to be
maintained in such a way that it will not contribute towards contamination of coconut
products. The elements in the buildings e.g. the drainage, the floor material and slope, the
walls, the ceilings that should be linear, the staff and toilet facilities to be located at an
appropriate site away from the processing area. Surfaces must be easy to clean and
maintain and the building must be pest proof to protect the finished product to potential
cross contamination from pests and environmental cross contamination.
Buildings should also meet the building codes of the relevant in country authorities as
required.
PRP - Transportation Receiving and Storage
The delivery truck or van for coconuts or products must be clean thoroughly for
transportation. The bags or bins used for storage in the farm at the receival end and for
storage of coconuts must be kept away from any chemical, biological or physical hazard
contamination.
PRP - Chemical Receival / Storage and Safe Handling

Documented methods of receival, storage and safe handling of all chemicals used by the
operation. This will also include label controls, safety and spill management. Chemicals
musty be appropriate and suitable for use in a food environments. They must be stored
correctly to prevent cross contamination of food products. Instructions to be available for
staff to ensure chemicals are used in line with manufactures recommendations and at the
correct dilution to avoid contamination. A chemical manifest is to be maintained listing all
chemicals on site.
PRP - Cleaning/Sanitation
See Module 5 for more details

Cleaning and Sanitation to be carried out in timely manner and factory, equipment, floor and
ceiling, walls and surroundings must always be kept clean. A list of equipment and areas
to be cleaned is to be listed and a schedule of cleaning program to be written whether daily
or weekly or monthly and people responsible identified. Chemicals to be used for cleaning
must be approved and managed as listed in the chemical handling PRP

PRP - Good Hygienic Practice (GHP)
Procedures
Documented policies on Good Hygienic practices should be developed to include
clothing, i.e. type of outfit to wear in the processing area which must be clean and washable.
Some companies provide the uniforms for workers and this must only be worn for work
purposes. Food Hygiene Protocols includes procedures and practices that reduce the
likelihood of transfer of harmful microorganisms from human sources.
Proper staff hygiene
Procedures for proper staff hygiene, what to do when staff are sick must be well
documented. Some habits like smoking and spitting must be clearly stated and appropriate
places be designated for such activities. No eating is allowed while working but only at
designated eating place. The use of waste bins and its cleanliness, and stock rotation, etc.
should be clearly defined.
Personal hygiene can influence food poisoning. Personal Hygiene is very important and
should have special meaning to:
a) Food Handlers
b) Caterers
c) Food processors
d) all those involved with Food preparation
Normal unconscious body habits like scratching an itchy ear, nose, face, hair or body do
not create any problem in normal life but can lead to disaster when handling foods.
All employees must be trained on good hygiene practices and ensured that they understand
its importance. Employees must be made aware of how to practice good hygiene means
and wear appropriate clean clothing and Practice Good habits all the time. Any food borne
illnesses, cuts and wounds must be reported to management and must be dressed
thoroughly and whoever is affected must stay at home until the sickness gets better. Some
healthy people are carriers i.e. they have harmful bacteria in their bodies but do not suffer
any harmful effects.
Examples:
• Staph. Aureus ~70% population carry this organism in their nose without any
symptoms
• Salmonella/Clostridium perfringes can be present in the intestine of very healthy
people
Body habits below must be avoided when handling food
a) Scratching or combing the hair.

b) Wiping perspiration e.g. rubbing the armpits.
c) Stroking moustaches, beards, etc. This spreads Staph. aureus into the hands.
d) Smoking in the kitchen/processing area.
e) Handlers smoking should wash their hands before resuming work.
f) Coughing and sneezing over the food.
g) Running index fingers along a running nose.
h) Picking pimples.
i) Tasting food by using the fingers or a spoon that is returned to the food with saliva
on it.
j) Licking the fingers to separate wrapping papers, transfers saliva

Monitoring
To monitor the above activities supervisors are to carry out internal checks or internal audits
and ensure all procedures are followed.
Corrective action
This occurs when staff are found not adhering to procedures, to improve, staff training or a
change in the system are implemented.
Records
For all activities above an assessment of procedures and implementation to be recorded
including any corrective action carried out.
PRP - Pest Control
Document procedures
The purpose of the Pest Control Programme is to prevent and control the movement and
breeding habits of birds, rodents, spiders and insects. The pest control programme will
a) Identify pests to eradicate and developed procedures of pest control activities either
through chemical means or baits etc.
b) With the use of chemicals, a Material Safety Data Sheet (MSDS) must be
accompanied with the chemicals supplied and proper instruction of how to use and
when to use, frequency of usage and what area or location to be identified.
c) An alternative is to contract a professional Pest Control company to look after this
area of control for the business.
Monitoring
Internal control on pests’ eradication should be implemented through internal checks or
audit to ensure the chemical use and frequency of application is effective.
Corrective Action
Good housekeeping to remove Harbourages, food and water is one of the most effective
ways to prevent pests from contaminating products and packaging.
They are response measures in the case of ineffective control, staff are to be trained or
change the contract with the professional pest control company.
Records
This will include assessment of the pest control activities and what corrective action taken
regarding product.

PRP - Training
Documented procedure
The training protocols at the operation, providing for both the planning and progress
tracking of employee training and thereby ensuring all staff are sufficiently qualified to
perform their particular jobs and quality related duties. The training protocols will apply to
all employees.
The purpose of the Staff Training Programme is to ensure that the business does not create
any food safety or quality problems based on staff handling raw materials and finished
products. This procedure will cover who’s responsible, scope, detailed procedure of the staff
training programme, monitoring of staff training and records.
There needs to be a training plan for critical activities to be undertaken by appropriately
trained operators. This should be including a training matrix that will identify who is to be
trained and in what area and when. It will also assist in identifying who is capable to train
others.
Monitoring
Regular reviews of performances of staff to assess understanding of program and its
implementation. This can be carried out management or HACCP team leader.
Corrective Action
For inefficiency or lack of understanding and confusion of implementation, a re-training to
be carried out on identified aspects.
Records
Training records must be kept and reviewed for continuing capacity building and upgrading
skills. This will include a Training Plan and matrix

PRP - Document Control
Documented procedure
The purpose of the Document and Data Control Programme is to ensure the Food Safety
Programme is maintained to the latest document issue. Records raised provide objective
evidence of our operational activities. This procedure will cover who’s responsible, scope,
detailed procedure, monitoring of Document and Data Control and records.
Documents here include the Food Safety Manual, The standard operating Procedures and
the Good Hygienic and Manufacturing Practices. It is important that these documents are
compiled and made available for all team members to read, understand and follow. Each
document must be identified by file name and number e.g. FS0118 for maybe Food Safety
Manual 1 of 2018. etc. All documents must first be checked and approved for use by
management before use. The location of documents i.e. where it is kept must be known for
ease of access. Any changes that are carried out to the documents because processes
and methods may have changed must be noted and the changes recorded.
Monitoring
The HACCP team leader should now and then check or carry out an Internal Audit yearly
or half yearly to ensure procedures are intact and to ensure that any changes to the process
flow has been adapted. HACCP system documents are to be reviewed annually
Corrective Action
If through audits the documents are found to be non- complying to actual operations, then
the documents must be amended to fit the changes.
Records
Changes in the documents and any non-compliances from auditing must be recorded and
registered and any corrective actions carried out during auditing must be documented and
filed. Amendment register for documents to be maintained. All documents to be dated
and labelled appropriately

PRP - Product Identification and Traceability
Documented procedures
The purpose of the Product Identification and Traceability Programme is to ensure that the
business is able to perform efficiently and effectively the identification and traceability of all
raw materials to our processing plant and all finished products to our customers. This
procedure will cover who’s responsible, scope, detailed procedure, monitoring of Product
Identification and Traceability and Records.
Further information can be found in Module 7
Monitoring
Includes on-line checks as products received, handled and packed. Regular verification
of records is required to confirm that all systems are in place to maintain accurate records
of all steps in the production process. A mock recall will be completed annually to confirm
systems re working OK
Corrective action
To be carried out when errors encountered.
Records
It is important to record the on-line checks and the corrective actions carried out from errors
encountered.
PRP – Product Recall
A recall is defined as any “action taken to remove from sale, distribution and consumption
foods which may pose a safety hazard to consumers”.
The event of a food recall is a most serious occurrence. Rapid response to all required
actions is imperative to limit effects on public health and the business.
The purpose of the Food Recall Programme is to ensure that the business is able to perform
efficiently and effectively in the need of a product recall situation. This procedure covers:
Responsibilities, Scope, detailed procedure of the Food Recall programme, Monitoring of
Food Recall situations and Records.
Recalls are often managed by authorities such as FSANZ (Food Standards Australia and
New Zealand). Excellent systems and protocols are available on the FSANZ web site.
http://www.foodstandards.gov.au/
PRP - Mock Recall
Product Recall occurs when Customers are complaining and not happy with the product
supplied and are refusing to buy. There could be a major problem with products supplied.
For example, a product may cause sickness to someone or more customers which may
results in rejection of product. The product will eventually be returned to the manufacturer
of distributor for reimbursement of sales or replacement for whatever cause it may be. In
such cases there has to be a recall procedure in place and management and staff or the
HACCP team should be well aware of what to do in such a situation.
The Mock Recall is all a pretence activity of above where the team assumes there is a
problem and they develop procedures to assess or to solve the situation. What is important
in this exercise is that it tests the accuracy of recording as well as the traceability in place.
It also assists the staff to be aware of what to do, who to contact and how to communicate
responsibly to stakeholders.
PRP - Allergen Control
The purpose of the allergen management programme is to eliminate the risk of an allergen-
related recall by minimizing the risk of cross-contamination of food products from
undeclared allergens.
A policy on Allergen control to be in place indicating precautions of any ingredients or
products produced that may cause allergic reaction and harm to consumers. It is important
to be aware of products or produce that causes allergies to customers. This product is to be
identified, described and stored and sealed well. A register of Allergen items must be kept
and updated and controlled.
PRP - Labelling
Product Labelling & Specifications Procedures ensure the products stored in the facility are
dated and labelled in the correct manner and products are not used after the expiry of the
shelf life. All ingredients will have a suitable raw material specification held on file.
a) Labelling must comply with FSANZ Label Standard Code:

b) See >> http://www.foodstandards.gov.au/industry/labelling/pages/default.aspx
c) This provided an excellent guide and standard in the absence of Local or In
country standards.
Individual labelling standards (e.g. Date of marking of Packaged Food)
• Individual product group standards e.g. Standard 2.2.1; Fish and

Fish products)
• Trade Weights and Measures Legislation- covering weights,
deceptive packaging etc.
b) Labelling Laws that may apply include:

• English language: size and contrast of print
• Street address: weight /volume of product
• Ingredient list: correct declaration of additives
• Warning statements and Allergen declaration
• Date/ Lot coding
• Nutrition Information (NIP)
• % characterising of ingredients
• Declaration of irradiated & genetically modified ingredients
• Storage, Handling and preparation instructions
• Country of origin

PRP - Visitors Policy
Visitors to the factory is expected at any time, some through appointment and some not.
Thus, a policy regarding visitation to the factory must be established because visitors can
contribute to contamination of products or equipment or ingredients and packaging, if it is
not properly controlled.
A policy would indicate any boundaries or procedures or instructions that visitors must
follow. It must emphasise what area in the factory visitors can and cannot enter and how
to conduct themselves once they are allowed into the factory.
They may be required to wear protective clothing e.g. hairnets and proper foot wear and
coats as part of the strict maintenance and monitoring of hygienic practices in the
processing plant.
A book for registration of people visiting the premises must be kept being able to know who
visits and for what purpose.

PRP - Maintenance
Documented procedures
This programme is designed to reduce risks associated with repair or maintenance of
equipment in regards to contamination of food products. A list of equipment to be identified
and procedures of maintenance written down, e.g. lubrication, bearing changes, oil
changes, unscheduled activities. Schedule of Maintenance must be programmed when and
how and who to carry out.
Monitoring
For every maintenance of equipment or building the supervisor or person in charge should
monitor the servicing and repairs and ensure that all is done and completed, and machinery
is working well to be able to provide the “clear to go” advise.
Corrective action
For any work that may not be completed and need more work, a correction action to review
of appropriateness of service etc. will be taken.
Records
All records of job orders and equipment and machinery or building repaired or serviced to
be maintained.
Other issues to consider are the type of:
a) grease to be food grade

b) Control of sub-contractors
c) Count-in and count-out of tools
d) Inclusion of maintenance staff on food safety plan deliberations

PRP - Calibration
The purpose of the Calibration Programme is to ensure that measuring instruments are
accurately calibrated enabling accurate readouts. It is necessary to ensure that equipment
used to monitor critical control points is in good working condition and checked regularly to
ensure it is effectively calibrated. Calibration deals with any measuring equipment where it
is compared to a know value to confirm its accuracy. Eg Boiling water = 100 °C
E.g. scales for weighing, thermometers or thermostat for measuring temperatures,
volumetric meter for measuring volume, pH measurement etc.
Depending on the frequency of usage, this equipment should be standardised against a
standard equipment annually to ensure it is reading the correct measurement.
A Documented procedure where one:
a) Identifies the equipment to be calibrated

b) Write down the method of calibration to be used and
c) What frequency of calibration or how often should the equipment be calibrated
i.e. either six monthly or yearly
Monitoring
There is a need to monitor the calibration checks of weights and scales and if the
scale is faulty something must be done about it and it is called corrective action.
Corrective Action
Is the activity taken when equipment is found not be reading correct measurements?
It must be noted what corrective action was performed on what equipment on what
day and who performed it.
Records
All these activities must be recorded for future references. If the equipment has been
replaced or sent for repair, where, when and by whom etc. must all be noted.

PRP - Verification
The purpose of the Verification PRP is to Review the system to ensure that the all
components are operating in the correct manner and all records have been maintained.
Verifications can be completed with simple checklists or Audits see below.

Verification activities also involve other PRP’s such as Calibration, Internal / External or
supplier audits.
Some testing like micro, chemical or physical testing of raw ingredient or finished product
can also be part of Verification activities.
A mock recall verifies that labelling & traceability systems are working OK. Some facilities
also complete verification of cleaning using protein swabs.
The purpose of the Annual Food Safety Programme Review is to take some time to review
all Documents within the Quality manual to check they are still relevant and to verify is any
updates or amendments are required to keep them current.
PRP - Auditing
The purpose of the Internal Audit Programme is to ensure that the Food Safety Programme
operates effectively and efficiently. This procedure will cover who’s responsible, scope,
detailed procedure, monitoring of the Internal Audit Programme and records.
External Audits are conducted by someone who is outside the business that provides an
independent review that the HACCP Systems as documented in the HACCP manual have
been maintained in an appropriate manner. These audits are completed against a relevant
standard and a report and Certificate are normally issued. This provides an independent
review to which then give customers comfort that systems have been maintained correctly.
Actions taken to rectify non-conformances are documented in the Corrective Action System
PRP – Corrective Action system and complaints
The purpose of the Corrective Action Programme is to ensure that the business handles
corrective actions identified efficiently and effectively. Corrective action is mandatory action
to be taken when a deviation to the HACCP Food Safety Programme occurs, for example,
if product does not meet critical limits, customer complaints, supplier complaint. The
business will use each incident as an opportunity for improvement.
This procedure will cover who’s responsible, scope, detailed procedure, monitoring of
Corrective Action and records.
The purpose of the Customer Complaint Programme is to ensure that our customers have
an efficient and effective means of communicating any concerns or issues involving the
business. This procedure will cover who’s responsible, scope, detailed procedure,
monitoring of Customer Complaints and Records.
The Customer Complaint Register shall be used to verify the effectiveness of the Food
Safety Programme.

PRP - Organic Systems
The Purpose of this Organic PRP is to detail the procedure for handling, packing, storage
and distribution of organic goods to ensure the products are managed as per the standards
required.
Equipment which is to be used in the operation must be maintained in a clean and sanitary
condition minimizing the risk of cross contamination. Ensure that traceability is maintained
for organic products
Key Organic Control Points
• Traceability of organic products must be maintained at all time

• Cross contamination of organic and non-organic products must be minimised or
avoided.
• Ensure the correct procedures are followed for cleaning equipment
• Ensure that the organic standards as documented in our OMP have been met as
required.
• Records must be correctly maintained to ensure organic products are meeting the
requirements of the Selected Organic standard.
Organic standards have a considerable amount of requirements which are in line with
HACCP. Please take care not to duplicate systems and records and try to incorporate your
organic requirements into your HACCP systems and use the same manual and records
where appropriate
PRP - Food Defence - TACCP & VACCP
Food Defence is having plans in place to reduce the chances of someone intentionally
contaminating the food supply in order to kill or harm people, disrupt the economy or destroy
a business.
Protecting food from intentional contamination requires the practices of food Defence
strategies. Food Defence is a relatively new, however, extremely important concept due to
the many vulnerable access points in the farm to table food supply.
Threats to the foundational aspects of everyday life have the potential to cause a great deal
of harm such as physical, economic, psychological, and political.
The benefits of having a Food Defence plan will contribute to a safer and more secure food
supply. It will protect public health, employees and livelihood of the business.
A functional Food Defence Plan will also help to:
• Reduce the risk of unsafe product and economic loss

• Reduce theft
• Reduce the need for additional regulations on food Defence
• Reduce company liability

Module 7: Traceability & Recall
Objective
1. identify the process of recall and traceability

2. Importance of proper recording of the supply chain i.e. Suppliers to delivery to
processing then dispatch
3. Proper batch coding of finished product to reflect the source and date of processing
4. Importance of proper record keeping
5. Importance of team work
Traceability
The ability to follow the movement of food through specified stage(s) of production,
processing and distribution - from the raw material suppliers, receipt of raw materials,
though the processing stages, storage and transportation of product to the customer (mod.
Codex Alimentarius, 2004)
Coconut Supplier Coconut Supplier Coconut Supplier

Farmer Farmer Farmer

Figure 10: Traceability Flow chart


Recall
A food recall is the action taken to remove from distribution, sale and consumption any
food product that is deemed unsafe for consumption. Traceability is a vital component of
the recall process.
Document System
Documentation at each stage of production is essential, this will make it possible to trace
all actions taken
Important elements of the document system according to the 6 Ms:
a) Materials - Lot number, expiry date

b) Means - all equipment used and all operations performed on it: equipment life
expectancy sheet.
c) Methods - all procedures and instructions used: formulas explained and mode of
operations
d) Environment - all external conditions that may have an impact on quality: cold
chain, bacteriological monitoring
e) Manpower - all active staff, including their qualifications and continuous training
programs
f) Management - all information to ensure control management and enforce the
implementation of procedures related to quality and traceability.
Examples of Traceability evidence used in a recall exercise:
Paperwork that articulates the following information form farmer level, receipt of raw
materials, processing to the consumer (forms, records, reports statements etc.)
a) Raw material supplier

b) Raw materials receipt - dates and quantities
c) Processing steps - methodology, raw materials and quantities
d) Any rework
e) Waste generated
f) Processing records - batch numbers, quantities, observations and staff working at
the shift.
g) Number of units manufactured on the day for each recalled product type
h) List of customers who were sold the affected product
i) The quantities of affected product that each customer received
j) Reports on any affected product that has yet to be sent to customers. These maybe
still stored in warehouse storage areas
k) Any write-offs or stock waste that occurred for the finished product
l) Reconciliation reports of units manufactured to units sold to waste to warehouse
storage

RAW MATERIALS TRACABILITY –

RECORDS AT EVERY STEP
PROCESING 1
TO LINK THE STEP BEFORE AND STEP AFTER
PROCESING 2
PACKING
STORAGE
DISTRIBUTION
SHIPPING /
Customers
PRODUCTION PACKING
RECORDS RECORDS – STOCK
RECIEVAKL BATCH USEBY RECORDS Dispatch Documents
RECORDS CODES INVOICE
DELIVERY NUMBERS
DOCKETS
Figure 11: Traceability Flow chart – between processed

Module 8: Quality
Objectives

1. Identify characteristics that classifies a quality coconut product.
2. Identify the difference between Food Quality and Food Safety
Food Quality
Food quality is an important food manufacturing requirement, because food consumers

require wholesomeness in the food that they buy in terms of its organoleptic properties.
One must understand the difference between Food Quality and Food Safety. Food may
have good quality but may be unsafe to consume. Quality deals with the physical and
organoleptic characteristics of food. E.g. colour, texture, taste, form and shape etc. Safety
deals with the hygienic standard of what is to be consumed so that consumers are not
harmed.
Many consumers also rely on manufacturing and processing standards, particularly to know
what ingredients are present, due to dietary, nutritional requirements (kosher, halal,
vegetarian), or medical conditions (e.g., diabetes, or allergies).
Besides ingredient quality, there are also sanitation requirements.
It is important to ensure that the food processing environment is as clean as possible in
order to produce the safest possible food for the consumer.
Food quality also deals with product traceability, e.g. of ingredient and packaging suppliers,
should a recall of the product be required.
It also deals with labelling issues to ensure there is correct ingredient and nutritional
information.

Module 8: Quality
Essential composition and quality factors
Coconut Oil
Parameter Specification
pH 5 – 5.4
Brix 5 – 6.5
Total Aerobic Plate Count/mL Less than 5000
Coliform/mL Lee than 10
Faecal Coliform/mL Nil
Moisture and impurities (%) Max 0.5
Free Fatty Acid (%) Ma 4
Colour 4 – 12 Red
Iodine Value 7.5 – 10. 5
Saponification value (mg KOH/g oil sample 250 - 264
Coconut Water
Parameter Specification
pH 5 – 5.4
Brix 5 – 6.5
Total Aerobic Plate Count/mL Less than 5000
Coliform/mL Lee than 10
Faecal Coliform/mL Nil
Moisture and impurities (%) Max 0.5
Free Fatty Acid (%) Ma 4
Colour 4 – 12 Red
Iodine Value 7.5 – 10. 5
Saponification value (mg KOH/g oil sample - 264

Module 8: Quality
Good Practices to be followed for the production of high quality coconut

water.
Recommended practices Reasons/Comments
Coconut Selection and Handling and storage of Harvested Nuts - GAP
Select sound fully mature nuts, 12 – 13 Any younger or older and the taste of the
month old. They are light or yellowish coconut oil or product will have an off
brown in colour, hard brown shells, and flavour and an oily taste.
make a sloshing sound when shaken.
Select 9 month-old coconuts. (For Control the consistency of taste and collect
coconut water) the maximum volume of coconut water.
Do the husking in the early morning or in This is to ensure that the husked nuts are
a shady area. not exposed to sunlight and so maintain the
quality of the product.
Cover the pile of husked nuts as Exposure of nuts to direct sunlight for more
protection from direct sunlight. than an hour will cause the shell to crack.
The husked coconuts should not be This way coconut water flow can flow away
placed directly on a cement floor but on from the pile if coconut shell breakage
an elevated platform. should occur.
Do not store coconuts in plastic sacks. Since there is no air circulating inside the
sacks, moisture emanating from the fresh
nuts is trapped inside and will cause
deterioration of the nuts.
Do not allow coconuts to fall to the To avoid cracking of the nuts and spoilage
ground when picking. Nuts should be of the water.
harvested and lowered to the ground.
Nuts should not be allowed to come in To avoid contamination of the nuts and
contact with soil, and must always be in eventual contamination of the coconut
contact with clean surfaces. water.
Harvest and transport the nuts during the To maintain optimum quality of the coconuts
cooler parts of the day (early in the and water.
mornings or in the late afternoons).
The nuts should be randomly inspected To assure soundness of nuts and to detect
for signs of damage e.g. crack, bruises damaged nuts
and damaged nuts should be discarded.
The nuts must be stored in a clean, well To minimize contamination and to prevent
ventilated and shaded environment spoilage.
Grating
Before grating ensure that the grating To minimise microbial contamination

blades are thoroughly washed with soap
and water, and use hot water for the last
rinse.
Clean the grater blades and housing The risk is much higher in kernels of small
immediately after use. If necessary, use particles sizes because of the higher
pressurised water hose to to dislodge any surface area exposed for microbial
coconut kernel particles. contamination.

Module 8: Quality
Recommended practices Reasons/Comments
Drying
Dry the coconut kernel within 4 hours of Beyond 4 hours, the nut will yield yellow or
splitting the nut. pink oil due to microbial contamination that
would have occurred.
Dry the grated coconut kernel at the This is to prevent the kernel from burnt or
appropriate temperature (70 – 75 oC). scorched and result in yellow coloured oil. If
temperature is too low on the other hand
bacterial contamination may occur which
also results in yellow coloured oil.
Do not overload the dyer Overloading can cause deterioration of the
kernel that is not reached by heat and may
also result in yellow coloured oil.
Washing
The nuts must be washed in potable To remove dirt, debris and reduce the
water, followed by a mild bleach solution microbial load on the surface of the nuts.
The wash water must be frequently To avoid a build-up of dirt and
changed. microorganisms and possible
recontamination of the nuts.
Opening Nuts
Stainless steel cutlasses, must be used To avoid metallic contamination of the

for cutting open the nuts water.
The opened nuts must be checked for To detect and discard spoilt nuts
cracks or signs of spoilage.
Managing Coconut Water.
The coconut water must be filtered into a To remove undesirable particles, such as
sterilized glass or stainless steel fibre and pieces of shell, and to minimize
container. product contamination.
The coconut water must be rapidly cooled To slow microbial growth and enzymatic
to 4ºC. reactions
Fill coconut water into sanitized bottles To slow microbial growth and enzymatic
and immediately cool to 4˚C. reactions.
Transfer cooled bottles of coconut water To slow microbial growth and enzymatic
to chilled storage and maintain at about reactions.
4ºC.
Keep bottles of coconut water on ice (0- To maintain the quality of the bottled
4ºC) during distribution. coconut water.
Monitor retail outlets to ensure that To maintain the quality of the product during
product is stored at the correct display at points of retail sale.
temperature. Temperatures not
exceeding 4ºC.

References
1. Bawalan D. Divina. 2011. Processing Manual for Virgin Coconut Oil, its products
and by products for Pacific Island countries and Territories.
2. British Retail Consortium. 2015. Issue 7. www.BRCGlobalstandrad.com
3. “Enhance trade capacities of Pacific Agribusiness and Improve access to
International markets” Project n.074-15; Training the Trainers. October 11 -
October 21 , Suva, Fiji.
4. FAO - Coconut Water Production Good practice for the small-scale production of
bottled coconut water.
5. Fiji Islands Food Safety Act 2003.
6. Food Safety Regulations 2009, Fiji Islands. Legal Notice No. 20. Food and Safety
Act 2003, No 10 of 2003.
7. Food Safety System , EDES , a COLEACP programme; B-1050 Brssels Belgim
2011; www.coleacp.org/edes
8. HACCP Plans of Selected Coconut Food Products. 2006; Edited by Nina Loga -
Kindipan; Dina Boquiren-Masa; Manuel Mariano Garcia; Department of Agriculture;
Phillipine Coconut Authority, Research Development & Extension Branch; Dilman,
Quezon City, Manila.
9. Quality Management Systems. 2008. Requirements NZS ISO 9001: 2008;
Standards Australia Standards NZ. The Philippines Coconut Authority. HACCP
Plans of Selected coconut products.
10. The Candida Diet. https://www.thecandidadiet.com/ultimate-guide-to-coconut-
products/
11. The wonderful world of coconuts: https://www.marksdailyapple.com/the-
wonderful-world-of-coconut (from internet)
12. Training Manual Principles & Application of HACCP -NZ. AFS Food Safety Training
Course Manual.
13. HACCP Training Materials Developed by HACCP Australia Pty Ltd.

Appendix
Source: The examples given below have been extracted from Philippine
Coconut Authority Research and Development Branch, 2006. Selected
Coconut Food Products Manual & HACCP Australia Examples
Appendix 1: Virgin Coconut Oil (VCO) - Dry Process

Product Description
Important product Additive free, Pure coconut oil

characteristics
How it is used Taken orally - food supplement
Topical - skin and hair moisturiser
Packaging Glass jars: 250 mL, 500 mL
PET Bottles: 330 mL, 500 mL, 1L
Shelf Life 2 years
Where it will be sold Local and international markets
Labelling instruction • Dosage: 3 tablespoon a day, taken before bedtime or
1 tbsp after or before every meal
10. Manufacturer’s name and address

11. Best before:
12. Chemical/Physical description and composition
13. Nutrition value
Special distribution control Batch No.
List of Product ingredients and incoming materials

Name of Ingredients / Incoming Details
material
Husked coconuts l 11 to 13 months mature
l De-husked, without cracks
Filter papers l 5 Microns
l 0.5 microns
l Sterilized
Cheese cloth (Katsa) l White
l Clean without spots
Water l Potable
PET Bottes l Number 1

Appendix
Appendix 2: Example Product Description – Virgin Coconut Oil
Category:
• VIRGIN COCONUT OIL
Ingredients:
• Coconut oil
Storage & Shelf Life:
• Shelf life of virgin coconut oil is 12 months when stored in cool, dry, low humidity conditions.
• Virgin Coconut Oil is suitable for storage at ambient.
Product/Raw Material Sensitivity:
• The raw materials and finished products require handling, storage and distribution at ambient.
Coconuts must be free from cracks or splits in the shell, split or cracked coconuts will support
the growth of pathogenic micro-organisms.
• Coconuts must be harvested between 12-13 months for correct oil to moisture ratio for
processing. Over-mature nuts (greater than 13 months old) impart an off flavour and oily taste
so should be discarded.
• De-husked coconuts should be protected from direct sunlight.
• Coconut milk is a low acid protein food; this in addition to its high moisture content makes it
susceptible to microbial degradation.
Properties Critical to Safety:
• Virgin Coconut Oil is quality and microbiologically stable at ambient temperatures.
• Product must be free from extraneous matter, chemical contamination and levels of pathogenic
micro-organisms which could multiply to an infective dose under abuse conditions.
• Integrity of packaging.
• Product is sensitive to elevated temperatures and exposure to light, oxygen and water which will
cause rancidity of the oil.
• Moisture <0.1%
• Free Fatty acid ≤0.2%
• Peroxide Value ≤3.0mEq/kg
• Total Plate Count <0.5
Processes Critical to Product Safety and Quality:
• All raw materials must be produced, harvested and stored under appropriate food-safe
protocols including Agricultural Chemical controls and withholding periods.
• Product must be processed and packaged under hygienic conditions whilst conforming to all
critical limits and GAP, GMP & GHP.
• Coconuts must be processed within two days of being de-husked and within seven days of
being harvested.
Product Usage:
• The product is intended for use as an ingredient or in cooking and may undergo heat treatment
prior to consumption.
• The product is intended for distribution to the wholesale sector in both the domestic and export
markets.
• The product is intended for general population consumption.
Abuse Potential:
• Abuse potential is minimal although handling of product is critical to maintaining integrity of
primary packaging.
• Product is sensitive to elevated temperatures and exposure to light, oxygen and water which
will result in rancidity.
Packaging:
• Food grade PET bottles and IBC bulk containers.
Distribution:
• Products are suitable for distribution at ambient in a suitable food transport vehicle.
Special Labelling Requirements:
• Product must be labelled in accordance with the relevant legislation.
Sensitive Population:
• Nil.

Appendix
Appendix 3: Example – Flow Chart Hazard Analysis – Virgin Coconut
Oil
Virgin Coconut Oil - Process Flow Chart
C1 Receive matured coconuts at factory -

CCP1, CCP2, QCP1
C2 Sorting and cleaning of coconuts
C3 De-shelling coconuts CCP3
C4 Grating
C5 Weighing
C6 Drying
C7 Pressing
C8 Filtration
C9 Settling
C10 Virgin Coconut Oil Packing QCP2, QCP3
C11 Packed into cartons and ready for dispatch
C12 Store - Ambient
C13 Dispatch
Verified By:________________________ Date:______________
OPERATION INSPECTION STORAGE TRANSPORT DELAY
Hazard Analysis - Virgin Coconut Oil Page 1 of 1 Version 1 Issued May 2018

Appendix
Appendix 4: Example – Hazard Analysis – Virgin Coconut Oil

HAZARD ANALYSIS
PRODUCT Hazard Analysis

Process Step
C1 LINE Virgin Coconut Oil
Receive matured coconuts at factory - CCP1, CCP2, QCP1 CATEGORY Virgin Coconut Oil
OPEN / CLOSED TEMPERATURE UTILITIES INGREDIENTS / ADDITIVES PROCESSING AIDS / MATERIALS / EQUIPMENT
Ambient
Open Coconuts Trucks, Forklifts, Pallets, Bags
RISK
C P M HAZARD AND CAUSE Significance CONTROL MEASURES CCP / REF.
Sev. Lik.
Contamination of materials due to poor Inspect transport vehicle at each delivery, noting
ü ü ü transport conditions or accompanying 2 C Medium condition and accompanying goods. Transport vehicles CCP1
materials. not to carry chemicals or any non food-grade materials.
Do not accept or process any nuts that are cracked or

Loss of sterility of coconut resulting in
split. Visual inspection of coconuts at point of receipt for
ü potential microbial contamination of the 4 C Extreme CCP2
immature, germinated or damage i.e. cracked or split
coconut flesh.
shells or deteriorated eye.
Early or late harvesting of coconuts

Ensure coconuts are only purchased from Approved
resulting in the incorrect maturity of the
Quality issue only - not a food Suppliers meeting agreed raw material specifications.
coconut for processing. Only mature nuts QCP1
safety hazard Visual inspection of coconuts on receipt for compliance to
(12-13 months old as they have the highest
specification.
oil content and lowest moisture content).
Loss of traceability due to incorrectly On receipt of goods, inspect materials for lot ID and Prerequisite
ü ü ü 1 C Low
logged lot ID ensure data is noted on delivery documentation (Traceability)
Prerequisite
Ensure staff maintain personal hygiene & wear
ü ü ü Cross contamination from human sources 3 B Medium (Food Hygiene &
appropriate clothing
Clothing)

Appendix
HAZARD ANALYSIS

Process Step
Sorting and cleaning of coconuts CATEGORY Virgin Coconut Oil
Open Ambient Coconuts De-husking Equipment
RISK
Sev. Lik.
Ensure all staff responsible for de-husking are trained in correct

Loss of sterility of kernel during the de- Prerequisite
procedure and comply with hygiene standards. Do not process
ü ü husking process due to lack of controls in 2 C Medium (GMP &
any split or cracked coconuts. Quarterly GMP audits to verify
place or cracked / split coconuts. Training)
compliance.
Deterioration of de-husked coconut and Ensure all staff are trained in correct procedure and comply
loss of product integrity due to lack of with hygiene standards. Quarterly GMP audits to verify Prerequisite
ü ü controls within the processing plant and 2 C Medium compliance. De-husked coconuts should be processed within (GMP &
delays in processing the de-husked two days of being de-husked and within seven days of being Cleaning)
coconut. harvested.
Exposure of de-husked coconuts to direct

Prerequisite
sunlight resulting in cracked shells and Ensure de-husked coconuts are not exposed to direct sunlight.
ü 4 C Extreme (GMP &
potential microbiological contamination of Quarterly GMP audits to verify compliance.
Training)
the coconut.
Prerequisite
Ensure staff maintain personal hygiene & wear appropriate
ü ü ü Cross contamination from human sources 3 C High (Food Hygiene
clothing.
& Clothing)
Ensure operation contact surfaces & overheads are clean Prerequisite

Cross contamination from environmental
ü ü ü 2 C Medium Visually inspect equipment after cleaning or prior to start-up to (GMP &
sources
ensure all equipment is clean. Cleaning)

Appendix
HAZARD ANALYSIS

Process Step
De-shelling coconuts CCP3 CATEGORY Virgin Coconut Oil
Open Ambient Coconuts Equipment, Knives, Benches, Containers
RISK
Sev. Lik.
Ensure staff maintain personal hygiene & wear Prerequisites

appropriate clothing Clothing)
Loss of Traceability could cause difficulty in Ensure Lot ID's are assigned to each batch of coconuts Prerequisite
ü ü ü 1 C Low
effecting a product recall processed to allow for traceability of stock. (Traceability)
Processing of coconuts that have started to Ensure all coconuts processed have opaque white flesh
ü deteriorate resulting in inferior finished 2 C Medium that is firm in texture. Do not process any coconuts that CCP3
product. have discoloured or slimy, soft textured flesh.

Appendix
HAZARD ANALYSIS

Process Step
Grating CATEGORY Virgin Coconut Oil
Open Ambient Coconuts Equipment, Grater, Benches, Containers
RISK
Sev. Lik.

Clothing)
Loss of Traceability could cause difficulty in Ensure Lot ID's are assigned to each batch of coconuts Prerequisite
ü ü ü 1 C Low
effecting a product recall processed to allow for traceability of stock. (Traceability)
Processing of coconuts that have started to Coconuts must be processed within fours hours of the
Prerequisite
ü deteriorate resulting in inferior finished 2 C Medium shell being broken or the nut being split. Ensure
(GMP)
product. operators are trained in correct procedure.
Ensure materials are processed in such a way to avoid all
potential for cross-contamination. Prerequisite
Ensure that pest control activities are effectively (GMP, Pest
ü ü ü Contamination from environmental sources 2 C Medium maintained. Preventative Maintenance programme in Control,
place to ensure plant and equipment are in good Maintenance,
condition. Cleaning procedures in place to ensure all Clean)
equipment is cleaned appropriately.
Processing of coconuts that have started to Ensure all coconuts processed have opaque white flesh
Prerequisite
ü deteriorate resulting in inferior finished 2 C Medium that is firm in texture. Do not process any coconuts that
(GMP)
product. have discoloured or slimy, soft textured flesh.
190304 HACCP
Hazard Manual
Analysis - Virgin SPC Coconuts March 2019.docx
Coconut Oil Page 5 of 14 Page 71 of 83 Version 1 Issued May 2018
Appendix
HAZARD ANALYSIS

Process Step
Weighing CATEGORY Virgin Coconut Oil
Open Ambient Coconut Flesh Scales, Benches, Containers
RISK
Sev. Lik.
All personnel entering premises must follow strict hygiene

Contamination of coconut via operator or Prerequisites
standards. Utensils & tools to be inspected prior to use &
ü ü ü equipment through introduction of dirt etc. via 2 C Medium (Food Hygiene &
approved by management. All operators are required to wear
clothing, hands, hair, utensils, tools. Clothing)
hairnets & clean uniform for cleaning & operation activities.
Ensure all product surfaces are cleaned as per the documented Prerequisite
Contamination of coconut via residues from
ü 2 B Low cleaning procedures. Routinely inspect equipment for (GMP &
chemical cleaners or sanitizers.
cleanliness and condition prior to use. Cleaning)
Ensure materials are handled in such a way to avoid all potential

for cross-contamination. Ensure that
Prerequisite
pest control activities are effectively maintained. Preventative
ü ü ü Contamination from environmental sources 2 C Medium (GMP, Pest
Maintenance programme in place to ensure plant and equipment
Control)
are in good condition. Ensure overheads are clean and in a
good state of repair.

Appendix
HAZARD ANALYSIS

Process Step
Drying CATEGORY Virgin Coconut Oil
Open Ambient Coconut Drying Equipment, Benches
RISK
Sev. Lik.
Prerequisites
Failure to remove all residual water from Ensure all residual water is removed from coconut in
Prerequisite
the coconut resulting in loss of shelf-life Quality - not a food safety issue order to maintain product integrity and shelf-life. Water
(Gmp, Train)
and rancidity. content must be below 0.2%.

potential for cross-contamination.
Ensure that pest control activities are effectively Prerequisite
(GMP, Pest
ü ü ü Contamination from environmental sources 2 C Medium maintained. Preventative Maintenance programme in
Control, Clean,
place to ensure plant and equipment are in good Maintenance)
condition. Cleaning procedures in place to ensure all

Appendix
HAZARD ANALYSIS

Process Step
Pressing CATEGORY Virgin Coconut Oil
Open Ambient Coconut Flesh Press, Benches, Containers
RISK
Sev. Lik.
All personnel entering premises must follow strict hygiene

Contamination of coconut via operator or Prerequisites
standards. Utensils & tools to be inspected prior to use &
ü ü ü equipment through introduction of dirt etc. via 2 C Medium (Food Hygiene &
approved by management. All operators are required to wear
clothing, hands, hair, utensils, tools. Clothing)
hairnets & clean uniform for cleaning & operation activities.
Ensure all product surfaces are cleaned as per the documented Prerequisite
Contamination of coconut via residues from
ü 2 B Low cleaning procedures. Routinely inspect equipment for (GMP &
chemical cleaners or sanitizers.
cleanliness and condition prior to use. Cleaning)
Ensure materials are handled in such a way to avoid all potential

for cross-contamination. Ensure that
Prerequisite
pest control activities are effectively maintained. Preventative
Maintenance programme in place to ensure plant and equipment
Control)
are in good condition. Ensure overheads are clean and in a
good state of repair.

Appendix
HAZARD ANALYSIS

Process Step
Filtration CATEGORY Virgin Coconut Oil
Closed Ambient Power Virgin Coconut Oil Filter
RISK
Sev. Lik.
Prerequisites
Clothing)
Failure to remove all particles from the oil Routinely monitor quality of oil to ensure the filtration Prerequisites
Quality - not a food safety issue
resulting in an inferior quality product. system is effective in removing all particles from the oil. (GMP, Training)

(GMP, Clean,
Pest Control,
condition. Ensure all equipment and plant is cleaned in
accordance with the documented cleaning procedures.

Appendix
HAZARD ANALYSIS

Process Step
Settling CATEGORY Virgin Coconut Oil
Open Ambient Power Coconut Oil Equipment
RISK
Sev. Lik.
Prerequisites
Physical contamination from suspended Prerequisite

Ensure staff are trained in correct operation of equipment (GMP, Clean,
ü impurities due to ineffective operation of 2 C Medium
and procedure. Filtrartion will remove any impurities. Train,
the settling process. Maintenance)

(GMP, Pest
Control, Clean,
condition. Cleaning procedures in place to ensure all

Appendix
HAZARD ANALYSIS

Process Step
Virgin Coconut Oil Packing QCP2, QCP3 CATEGORY Virgin Coconut Oil
Open Ambient Power Virgin Coconut Oil Packing Station, Scales, Food Grade Packaging Materials
RISK
Sev. Lik.
Prerequisites
Clothing)
Contamination of finished product from Purchase all packaging materials from approved suppliers.
ü packaging due to manufacturer of packaging 2 B Low Obtain a statement from supplier indicating packaging is suitable Prerequisite (ASP)
materials from non food-grade materials. for food contact.
Loss of seal integrity resulting in potential

contamination of finished product and absorption
ü 2 B Low Visually inspect packaging to ensure seal is intact. QCP2
of moisture and hence deterioration of product
quality.
Weigh each finished product at completion of packing to ensure

Finished product weight does not conform with Regulatory issue only - not a food
it complies with the specified weight. Routinely monitor and QCP3
the specification. safety hazard
record product weights during packing operation.
Food Handler to inspect each carton on completion of packing to

Loss of traceability over product if incorrectly Prerequisite
ü ü ü 2 C Medium ensure products are labelled correctly including legible and
labelled. (Traceability)
correct use by date. Record findings.
Loss of Traceability could cause difficulty in Ensure Lot ID's are assigned to each batch of Virgin Prerequisite
ü ü ü 1 C Low
effecting a product recall Coconut Oil processed to allow for traceability of stock. (Traceability)

Prerequisite
Ensure that pest control activities are effectively
maintained. Preventative Maintenance programme in
Control)
place to ensure plant and equipment are in good
condition.
190304 HACCP
Hazard Analysis -Manual SPC Coconuts March 2019.docx
Virgin Coconut Oil Page 11 of 14 Page 77 of 83 Version 1 Issued November 2018
Appendix
HAZARD ANALYSIS

Process Step
Packed into cartons and ready for dispatch CATEGORY Virgin Coconut Oil
OPEN / CLOSED UTILITIES INGREDIENTS / ADDITIVES PROCESSING AIDS / MATERIALS / EQUIPMENT
Open Virgin Coconut Oil Bench, Packaging Materials
RISK
Sev. Lik.
Prerequisite
Ensure staff maintain personal hygiene & wear appropriate
ü ü ü Cross contamination from human sources 3 C High (Food Hygiene
clothing.
& Clothing)
Ensure operation contact surfaces & overheads are clean Prerequisite

ü ü ü 2 C Medium Visually inspect equipment after cleaning or prior to start-up to (GHP &
sources
ensure all equipment is clean. Cleaning)
Food Handler to inspect each carton on completion of packing

Loss of traceability over product if Prerequisite
ü ü ü 2 C Medium to ensure products are labelled correctly including legible and
incorrectly labelled. (Traceability)
correct use by date. Record findings.
Appendix
HAZARD ANALYSIS

Process Step
Store - Ambient CATEGORY Virgin Coconut Oil
Closed Ambient Virgin Coconut Oil Racking, Pallets, Storage containers
RISK
Sev. Lik.
Loss of Traceability could cause difficulty in Ensure stock is correctly positioned so that Lot ID's are easy to Prerequisite
ü ü ü 1 C Low
effecting a product recall read and allow for correct stock rotation. (Traceability)
Storage of virgin coconut oil in high

Ensure virgin coconut oil is stored in low humidity warehouse Prerequisite
ü humudity conditions resulting in loss of 2 C Medium
to prevent absorption of moisutre and loss of product integrity. (GMP)
product integrity.
Ensure materials are stored correctly in such a way to avoid all Prerequisite
ü ü ü Contamination from environmental sources 2 C Medium potential for cross-contamination (GMP, Pest
Ensure that pest control activities are effectively maintained. Control)

Appendix
HAZARD ANALYSIS

Process Step
Dispatch CATEGORY Virgin Coconut Oil
Closed Ambient Virgin Coconut Oil Forklift, Pallet Jack, Trolley, Truck
RISK
Sev. Lik.

Clothing)
Visual inspection of vehicle prior to departure to ensure

vehicle is clean. Prerequisites
ü ü ü 2 C Medium Transport vehicles not to carry any chemicals or non-food (GMP, Cleaning
sources
grade product. & Sanitation)
Appendix
Appendix 5: Example – HACCP Plan – Virgin Coconut Oil
HACCP PLAN - VIRGIN COCONUT OIL

CCP CRITICAL CONTROL
CRITICAL LIMITS MONITORING CORRECTIVE ACTION REFER.
NO. POINT
1 TRANSPORT • THE CARGO AREA OF • What: Delivery vehicle • PRODUCT: Do not receive Work Instructions
CONDITION THE VEHICLE SHOULD • How: Visual inspection products until critical limits are met CCP001
BE CLEAN, PRODUCT • When: Each delivery or the non-conformance is rectified. APPROVED
ADEQUATELY Comments must be recorded on SUPPLIER
• Where: Loading dock
PROTECTED FROM THE RCV 001. PROGRAM
• Who: Receiving staff PURCHASE
ENVIRONMENT AND
SPECIFICATIONS
HAVE NO VISIBLE SIGNS • RECORD FINDINGS ON • PROCESS: Rectify the non- Receival form
OF POTENTIAL RCV001. conformance prior to taking receipt RCV001
CONTAMINATION OF of the product. Comments must be
ANY PRODUCT added on RCV 001.
2 COCONUT CONDITION • COCONUTS MUST BE • What: Coconut condition • PRODUCT: Work Instructions
FREE FROM • How: Visual inspection – Reject product affected. CCP002
GERMINATION, ANY • When: Each receival • PROCESS: APPROVED
CRACKED OR SPLIT – Inform supplier requesting SUPPLIER
• Where: Point of receiving on
SHELLS, THE EYE PROGRAM
site rectification.
MUST BE FIRM PURCHASE
• Who: Receiving staff SPECIFICATIONS
WITHOUT SIGNS OF
Receival form
DETERIORATION. • RECORD FINDINGS ON RCV002
RCV001.
3 COCONUT CONDITION • COCONUTS MUST HAVE • What: Coconut condition • PRODUCT: Do not process any Work
AT PROCESSING OPAQUE WHITE FLESH prior to processing. coconuts that have started to Instructions
THAT IS FIRM IN • How: Visual inspection. deteriorate and do not meet CCP003
TEXTURE. • When: Each batch prior to specifications. Record on PRO001.
processing. Production Form
• Where: Production • PROCESS: Inform the supplier of PRO001
• Who: Production Manager the non-conforming coconuts.
Record on PRO 001.
• RECORD FINDINGS ON
PRO001.

[VIRGIN COCONUT OIL.HACCP] PAGE 1 OF 2 Version 1 Issued May 2018
Appendix
HACCP PLAN - VIRGIN COCONUT OIL

CCP CRITICAL CONTROL
CRITICAL LIMITS MONITORING CORRECTIVE ACTION REFER.
NO. POINT
QCP1 COCONUT CONDITION • COCONUTS MUST BE • What: Coconut maturity • PRODUCT:
HARVESTED BETWEEN • How: Visual inspection – Reject product affected.
12-13 MONTHS FOR • When: Each receival • PROCESS: Work
OPTIMUM MATURITY. • Where: Point of receiving on • Inform supplier requesting Instructions
site rectification. QCP001
• Who: Receiving staff
RCV001
RCV001.
QCP2 PACKING - SEAL • EACH FINISHED • What: Seal integrity • PRODUCT: Inform Production
INTEGRITY PRODUCT MUST BE • How: Visual Inspection Supervisor requesting rectification
ADEQUATELY SEALED. • When: Every hour during and discard / rework non- Work
production. conforming product. Instructions
• Where: Production • WHO: Production staff QCP002
• Who: Production Staff • PROCESS: Arrange for repair of
equipment if necessary. PRO001
• RECORD FINDINGS ON • WHO: Production Supervisor
PRO001.
QCP3 FINISHED PRODUCT • FINISHED PRODUCT • What: Finished Product • PRODUCT: Work
WEIGHT WEIGHTS TO COMPLY Weight -DO NOT RELEASE PRODUCTS Instructions
WITH SPECIFICATION • How: Weigh & record 3 THAT DO NOT MEET CRITICAL QCP003
random weights of finished LIMITS.
products -RE-PACK UNDERWEIGHT PRO001
• When: At start of packing PRODUCT.
and every hour during • PROCESS:
packing. • -ARRANGE FOR CALIBRATION
• Where: Packing OF CHECK WEIGHER.
• Who: Packing staff.
PRO001.
[VIRGIN COCONUT OIL.HACCP] PAGE 2 OF 2 Version 1 Issued May 2018

Appendix
Appendix 6: Example – CCP Determination Questions – Virgin Coconut Oil
CCP DETERMINATION WORK SHEET – VIRGIN COCONUT OIL

Process Step C P M Hazard Control Measures CCP Decision Tree Questions (yes/no) Rationale
Q1 Q2 Q3 Q4 CCP/CP
Transport – Cleaning Dirt, plastic, Contamination Inspect vehicle for Y N Y N CCP1 Visual inspection of transport
Receiving chemicals stones, glass of materials due condition and presence condition at point of receipt to
goods to poor transport of any non-food grade identify potential contaminants will
conditions goods at each delivery. eliminate the hazard.
Receive and Microorganisms Microbiological Inspect condition of Y N Y N CCP2 Visual inspection of coconuts prior to
Inspect contamination of coconuts and record processing is necessary to identify
Coconuts coconut flesh findings. potential contaminants. No
due to splits or subsequent process step will
cracks in shells. eliminate the hazard.
Processing Microorganisms Processing of Inspect condition of Y N Y N CCP3 Visual inspection of coconuts prior to
Coconuts coconuts that coconuts being processing is necessary to identify
have started to processed to ensure deterioration of flesh. No
deteriorate they all have firm, white subsequent process step will
resulting in the flesh without any signs eliminate the hazard.
integrity of the of deterioration. Record
finished product findings.
being
compromised.

HACCP Manual SPC Coconuts March 2019 - Web

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

HACCP Manual SPC Coconuts March 2019 - Web

Uploaded by

Copyright:

Available Formats

190304 HACCP Manual SPC Coconuts March 2019.

190304 HACCP Manual SPC Coconuts March 2019.docx Page 2 of 83

190304 HACCP Manual SPC Coconuts March 2019.docx Page 3 of 83

190304 HACCP Manual SPC Coconuts March 2019.docx Page 4 of 83

190304 HACCP Manual SPC Coconuts March 2019.docx Page 5 of 83

190304 HACCP Manual SPC Coconuts March 2019.docx Page 6 of 83

190304 HACCP Manual SPC Coconuts March 2019.docx Page 7 of 83

§ Coconut water products 149%

190304 HACCP Manual SPC Coconuts March 2019.docx Page 8 of 83

The HACCP concepts are:

190304 HACCP Manual SPC Coconuts March 2019.docx Page 9 of 83

At the end of this module, participants should be able to:

Risk Management Strategy (RMS) is based on three basic principles

a) The Three Principles of RMS :

Examples: HACCP and Good Agriculture Practices (GAP).

• Decrease Food Borne Illnesses

HACCP or Food Safety Programs

a) A preventative system, not reactive

190304 HACCP Manual SPC Coconuts March 2019.docx Page 10 of 83

a) Identifies and analyses the hazards.

190304 HACCP Manual SPC Coconuts March 2019.docx Page 11 of 83

There are many advantages to be gained by your organisation, your community or

Description of the HACCP System

HACCP basic principles

HACCP is based on the 7 basic principles:

Figure 1: Principles of HACCP

190304 HACCP Manual SPC Coconuts March 2019.docx Page 12 of 83

PROCEDURE – 12 Steps to implement HACCP

1. Assemble HACCP team

Flowchart for the HACCP system

190304 HACCP Manual SPC Coconuts March 2019.docx Page 13 of 83

PRINCIPLE 3 PRINCIPLE 4 PRINCIPLE 5

Critical limits Monitoring System Corrective

Figure 2: Flowchart of the HACCP system

190304 HACCP Manual SPC Coconuts March 2019.docx Page 14 of 83

Apply using 12 step strategy that is divided into two phases

Step 1: Set up HACCP Team

Step 2: Describe the characteristics of the product

Step 3: Identifying the intended use of the product

Step 4: Construct the flow diagram

Step 5: Confirm the flow diagram on site

Step 7: Identify critical control points (CCP)

Step 8: Establish critical limits for each CCP

Step 9: Establish a CCP monitoring system

Step 10: Establish a corrective action plan

Step 11: Establish verification and review procedures

Step 12: Establish a documentation and record-keeping system

Figure 3: HACCP Application

a) documented control measures

190304 HACCP Manual SPC Coconuts March 2019.docx Page 15 of 83

1. Step 1: Setting up the HACCP Team

a) It must be a multidisciplinary team

2. Step 2: Describing the product characteristics

a) Description of the raw materials

3. Step 3: Identifying the intended us of the product

190304 HACCP Manual SPC Coconuts March 2019.docx Page 16 of 83

Figure 5: Basic HACCP Flowchart

5. Step 5: On-site verification/conformation of the flow diagram

This step involves the application of the 7 principles of HACCP.

6. Step 6: Conduct a hazard analysis (Principle 1)

Involves three steps:

a) identify hazards (chemical, biological or physical) at the different stages of the

190304 HACCP Manual SPC Coconuts March 2019.docx Page 17 of 83