Practical Manual—

Food Safety and Quality EXPERIMENT 3 DEVELOPING THE

Auditing
PROCESS FLOW FOR
THE FOOD
ESTABLISHMENT
INCLUDING ALL THE
INPUTS, OUTPUTS AND
INTERIM LOOPS
Structure
3.0 Objectives
3.1 Introduction
3.2 Principle/Rationale/Approach
3.3 Material Required
3.4 Experiment/Activities/Procedures
3.5 Observations
3.6 Result
3.7 Precautions

3.0 OBJECTIVES
After attending this practical, we shall be able to know:
l develop a clear and accurate description of the process flow; and
l understand the importance of this activity for successful FSMS.

3.1 INTRODUCTION
One of the major step is to produce flow diagram giving a clear, accurate and
simple description of all stages of the process from intake of raw materials through
processing to distribution, retail and consumer handling in accordance with the
scope of the study. The flow diagram should be constructed by the HACCP team.
The flow diagram should cover all steps in the operation. When applying HACCP
to a given operation, consideration should be given to steps preceding and following
the specified operation.

3.2 PRINCIPLE/RATIONALE/APPROACH
The step is critical for development of successful food safety management system.
The correct process flow chart helps in better and correct hazard assessment. The
team should confirm the processing operation against the flow diagram during all
stages and hours of operation and amend the flow diagram where were appropriate.
This activity ensures that none of the steps and conditions are missed out for
14 hazard assessment. The control measures are evaluated for each steps.
 Developing the Process
3.3 MATERIAL REQUIRED Flow for the Food
Establishment Including
The inputs from Experiment 2. all the Inputs, Outputs
and Interim Loops
3.4 EXPERIMENT/ACTIVITIES/PROCEDURES
A. Collect the data during the onsite visit for the production process.
B. Construct a flow diagram showing all major steps in a production process
from the begining to end including.
l all inputs such as water, steam, air, other processing aids,
l all processes of the product or intermediate such as mixing, handling,
transfer etc.,
l product recycle and rework loops,
l all outputs such as products, by-products, waste, and
l point of analysis.
C. The steps in the diagram should be numbered to ensure that there are no
misses.
D. The description should include all relevant process data such as:
l time, temperature, pressure,
l flow conditions for liquids, solids and gases,
l size of the product pieces, or batches,
l cleaning and disinfecting procedures,
l personnel hygiene practices,
l storage and distribution conditions (e.g. temperature, humidity), and
l consumer use instructions, etc.
E. Construct the facility layout of areas where a hygiene barrier is important.
F. The facility layout helps in identifying:
l floor plans and equipment placements,
l equipment design features including presence of void spaces,
l environmental hygiene (clean or dirty zone),
l interconnections and movements of products and personnel,
l personnel routes, and
l routes of potential cross-contamination.

3.5 OBSERVATIONS
l Completed Flow diagram.
l Completed facility layout. 15
Practical Manual—
Food Safety and Quality 3.6 RESULT
Auditing
Development of a process Flow sheet for a food establishment visited based on
your understanding of the subject.

3.7 PRECAUTIONS
l All the steps are to be put in the process flow at right order
l All inputs and outputs to be identified at the process flow.

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