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Biscuit
Development of a HACCP-based manufacturing
approach to control risk factors plant

associated with biscuit

manufacturing plant, Bangladesh
Suvasish Das Shuvo, Md. Shahariea Karim Josy, Rashida Parvin and Received 8 March 2019
Revised 31 March 2019
Md. Ashrafuzzaman Zahid 8 April 2019
10 April 2019
Department of Nutrition and Food Technology, Jashore University of Science and Accepted 10 April 2019
Technology, Jashore, Bangladesh, and
Dipak Kumar Paul and Md. Toufiq Elahi
Department of Applied Nutrition and Food Technology, Islamic University,
Kushtia, Bangladesh

Abstract
Purpose – The purpose of this study is to develop a hazard analysis and critical control point (HACCP)-
based approach to control risk factors associated with biscuit manufacturing plant.
Design/methodology/approach – Methodology was developed to achieve and implement the food
safety and quality requirements. Procedure for hazard analysis and risk assessment was based on ISO
22000:2005 and codex standard. The HACCP Plan was summarized in comprehensive figures and tables.
Biological, chemical and physical hazards that could exist in every step of biscuits production were identified.
Moreover, the critical control points were selected and the critical limits, monitoring, corrective measures,
records and verifications were established using risk analysis and decision tree.
Findings – With the implementation of HACCP system, it could be possible to reduce the food safety hazard
and provide safe food and increase customer satisfaction. The critical control points were identified in sieving,
sugar crushing, baking and detecting metal through the use of risk analysis and decision-making tree to
control the biological, physical hazards along with monitoring through the control sheets. Critical limits,
monitoring methods and frequency, responsibilities and corrective actions of the processes are also presented.
This measuring instrument could be used by a food company as assessment tool and a benchmarking tool.
Originality/value – Applying the HACCP system in food manufacturing can effectively assure food
safety and quality, as well as expand the market and improve the manufacturers’ management level. In doing
so, suitable strategies can be selected by a food company to allocate resources, increase HACCP effectiveness
and improve its product safety.
Keywords Food safety, HACCP, Food industry, Critical control point,
Monitoring and implementation
Paper type Research paper

1. Introduction
The food industry is responsible for producing not only safe foods but also for
demonstrating in a transparent manner how food safety has been planned and implemented.

The authors appreciate the cooperation of staff of central marketing company for conducting of this Nutrition & Food Science
study. © Emerald Publishing Limited
0034-6659
Disclosure statement. The authors report no conflict of interest. DOI 10.1108/NFS-03-2019-0074
NFS This is done through the development of a food safety management system (FSMS)
(Motarjemi and Mortimore, 2005). Food hygiene is a principal and widespread goal for the
food industry which includes the hygienic design and engineering of installations and
facilities, engineering of equipment and combination of components and maintenance (Betta
et al., 2011). Major financial, technological and managerial investments need to implement
FSMS along the agro-food chain (Jacxsens et al., 2010). On this point of view, hazard analysis
and critical control points (HACCP) and FSMS (Trafialek and Kolanowski, 2017), are widely
acknowledged as the best method of assuring product safety management that in the last
few decades has become an increasing part of national governments and international
strategy to reduce the prevalence of food-borne disease (CAC, 2003; Wallace et al., 2005).
HACCP is a systematic approach for the identification, evaluation, and control of hazards in
those steps in food manufacturing that is critical to food safety (Ropkins and Beck, 2000).
Good manufacturing practices (GMP), good hygiene practices, HACCP control and
production systems are used to ensure food safety. In addition, food safety systems are used
simultaneously with total quality management and should be implemented at every stage of
the food production “from farm to the fork” (Bas et al., 2007). The potential obstacles to
implement HACCP system are lack of expertise, legal requirements, financial constraints,
and attitudes (Route, 2001).
Practical experience and a review of food safety literature indicate that success of
developing, installing, monitoring and verifying effective HACCP system is dependent
on a complex mix of managerial, organizational and technical hurdles (Bas et al., 2007).
The major problems identified in the food industry have been reported as lack of
knowledge, training and the large variety of products, variation in potential demand,
workloads and large numbers of part-time workers (Adams, 2000; Route, 2001; Codex,
2009). Potential barriers to the implementation of HACCP need to be identified and
examined as an initial step for development of any HACCP implementation strategy.
These barriers vary from country to country or from sector to sector. Some may be due
to internal factors in individual businesses, e.g. the level of knowledge or resources
available to a business. Others may be due to external factors, such as the availability
of government or industry support (WHO, 1999). The implementation of FSMSs into
small production businesses is very difficult at the present time because such systems
are considered too complicated given the huge amount of documentation involved and
the need for additional economical resources (Le et al., 2014). That is why implementing
effective tools into HACCP would allow the management of hygienic processing and its
traceability.
Subsequently, HACCP is a world-recognized, effective, and preventive food hygiene
management system method to measure hazards, estimate risks and establish precise
control measures that emphasize prevention and control rather than reliance on end-product
testing and traditional inspection methods. At present, the HACCP system has been widely
adopted by many countries such as the USA, Japan, the United Kingdom and member states
of the European Union, as well as international organizations such as the World Health
Organization, Food and Agriculture Organization, and Codex Alimentarius Commission
(CAC) and have strict requirements regarding food imports (Zhu et al., 2003; Lu-li, 2011).
Traditional quality ensuring methods, which simply require inspecting the final products,
can no longer satisfy the consumers’ needs. Implementing HACCP is helpful for gaining
consumers’ trust and establishing a good corporate image. The application of HACCP
enables corporations in Bangladesh to break down trade barriers and participate in
international business, thereby effectively expanding their markets and increasing profits.
Additionally, a logical and applicable HACCP plan can help food factories to improve their Biscuit
management level and enhance their staff’s safety consciousness. manufacturing
Determining the factors linked to production and food handlers could help producers to
implement HACCP and reduce the likelihood of microbiological hazards, such as Escherichia
plant
coli, Salmonella spp. and Staphylococcus aureus in end products. Therefore, preventing
microbial contamination has been crucial for its safety control. HACCP has been proven to
be effective in inhibiting the growth of Staphylococcus aureus, Escherichia coli and other
human pathogens in biscuit production (Kokkinakis et al., 2008). The quality and safety of
the final product can be effectively guaranteed through the application of the HACCP
system (Table II) (Bureau of Standards, 2011).
In this methodological paper, the main objective was to develop a HACCP-based
approach to control risk factors associated with biscuit manufacturing plant,
Bangladesh. The approach is designed for use in biscuit production where a greater level
of control is desired for wider applicability. A secondary objective was to present the
evidence supporting the selection of critical control points (CCPs) along with targets and
critical limits.

2. Materials and methods

2.1 Study design
The research protocol was approved by the Review Board of Human Research Ethics
Committee of that Company and a signed consent was obtained for each participant besides
an ethical clearance was obtained from them.

2.2 Study area and object

The present study was conducted at Central marketing company (A high energy biscuit
factory), Jashore, Bangladesh. Total time period was from December 1 to December 30, 2018.
Total HACCP based approach gradually implemented and drastically reduced the food
safety hazard there.
The entire production process of biscuit was evaluated including safety control method,
condition of storage and distribution (Table II). The potential biological, chemical and
physical hazards that may exist in every step of the production process were identified and
then CCPs were selected. HACCP principles (Table I), developed by the CAC, 1997
(Commisssion, 1997; CAC, 2003) had been adapted for use at farm level (Cullor, 1995) and
summarized (Noordhuizen, 2008).

2.3 Methods
Based on the United Nations CAC’s HACCP and guidelines for its application (CAC,
2003; Codex, 2009), the overall technical process of biscuit production was drawn and a
hazards analysis was performed. The flow diagram consists in a detailed list of all the
stages needed to manufacture biscuit. The flow diagram also included the stages after
the product was obtained until it reaches the consumer which was checked on site by the
food safety team (Figure 1). Based on government regulations and industry standards,
pre-requisite programs (PRPs) and operational pre-requisite programs (OPRPs), CCPs
and critical limits were established, as well as monitoring procedures, corrective
measures, records, documentations and verifications. For proper monitoring daily work
checklist were developed for every processing steps and kept in place for proper
checking and for further actions as well as for traceability to search the root cause of
arising safety hazards. The decision tree method was implemented to select the CCPs
according to the procedures described in CAC (CAC, 2003) and Codex (Codex, 2009). This
NFS Step 1 Assemble a multidisciplinary, facility-based Quality Control Team
Step 2 Describe the final product
Step 3 Identify the intended use of the product
Step 4 Develop a flow diagram which describes the production process. Work from the whole farm level
to the detailing of separate steps up to the detailing within the steps
Step 5 Verify the correctness of the flow diagram with the team members and the food workers
Step 6 Prepare a list of steps in the production process at which targeted risks occur. Identify the
hazards and priorities them; identify the risks; conduct risk weighing
Step 7 Identify the CCP in the production process required to eliminate or reduce the hazards and risks
Step 8 Establish critical limits and standards, or specific targets for triggering the implementation of
corrective and preventative measures associated with each CCP identified in step 7
Step 9 Establish an on-plant monitoring program and its requirements regarding each CCP. Use the
results of monitoring to adjust the procedures and maintain control of the production process
Step 10 Determine corrective measures, to take when monitoring results indicate that a value falls outside
its target or tolerance level and hence control is lost
Table I. Step 11 Establish effective record-keeping procedures that document the HACCP-like program have been
implemented, is operational and effective
Steps taken in the Step 12 Establish procedures to verify that the HACCP-like program is working correctly (e.g. internal
development of a reviews yearly; external verification and audits; periodic revalidation of the program)
HACCP-based
program Source: Steps taken in the development of a HACCP-based program (CAC, 2003 and Codex, 2009)

method is a visual, easy to understand alternative to the numerical charts and other
decision analysis methods such as hazard analysis scheduling and spreadsheets. These
principles were applied in a systematic manner to the hazard ensuring that all relevant
activities on atypical food industries were addressed (Table II). The central concept of
HACCP is the identification of CCP and associated monitoring, corrective action and
verification procedures (CAC, 2003).
2.3.1 Hazard assessment. Hazards were identified from this study and were evaluated by
the food safety team at company premises. Hazards were categorized into biological,
chemical, physical and in some cases allergenic and it arises from contamination,
multiplication as well as persistence. The assessment procedures for the hazard were the
severity of known or potential adverse health effects and its probability of occurrence. After
this study, result was used to set different levels of severity and likelihood through using
score for each stage of manufacturing. Hazard was considered significant if the score found
above 4, after multiplication of likelihood (L) by the severity (S) values (L  S) (CAC, 1997;
ISO 22000, 2005; Fernandez-Segovia et al., 2014; Allata, Valero and Benhadja, 2017).
Likelihood and severity were evaluated according to the criteria and the scores described in
Table II.
2.3.2 Determination of pre-requisite program. Previous measures necessary to maintain
the quality of products are called PRP and PRP obtained from risk analysis and decision-
making tree (CAC, 2003).
2.3.3 Determination of critical control point. CCPs were subsequently selected from the
same risk analysis and decision-making tree basically following government regulations
and industry standards. Critical limits were established as well as monitoring procedures,
corrective actions, records, documentations and verifications (Ribeiro-Furtini and Abreu,
2006; Trafialek and Kolanowski, 2017). These answers not only measure product safety but
also to select CCP.
 Raw Material Receiving Wheat flour, Sugar, Vegetable Biscuit
oil, Vegetable fat, Soya flour, manufacturing
Ground water Common salt, Baking soda, plant
Filtration Micronutrients premix
Raw Material Mixing

k
Water tank
Temperature range
Dough Forming (PRP)
D
200 oC -300oC

Wheat flour + Soya flour Baking time 4-6 minutes

Rotary Molding
Ro
R
Receiving & Storage

Metal detection (CCP-1)

Baking (CCP-2)
Bak
Sieving (PRP)

Cooling (PRP)
Coolin

Sugar
Metal Detector
Detecto (CCP-3)
Receiving & Storagee

Crushing & Metal detection (CCP-1)

Stacking
acking
Heating (PRP)

Sugar Syrup Packaging and Cartoo

Cartooning (PRP)

Storage and Dispatch

Dispa
Salt, Vegetable oil, ammonium bi carbonate,
sodium bi-carbonate, micronutrients premix

Receiving
Figure 1.
Storage Flow diagram of
biscuit manufacture

3. Results and discussion

Hazard analysis was based on three hazards named (physical, chemical and biological)
hazard (Trafialek and Kolanowski, 2017). In this study, the objective was to determine
CCP’s and identifying the PRP’s and OPRP’s in biscuit plant. In this study CCP’s, PRP’s
and OPRP’s were identified through risk analysis and decision tree. Present study was
based on raw materials receiving, raw materials storage, raw mixing, dough forming,
rotary molding, and baking, cooling, metal detection; collect in striker, packaging and
cartooning and finally storage and dispatch. HACCP identification was a vital issue to
ensure safe products in each step (Table II).
 NFS

CCPs and
Table II.
Determination of

prerequisite program
Hazard Type Decision tree
Step Name (B,C,P)* Hazard Description Source Control Measure L* S* L  S Qa-1 Q-2 Q-3 Q-4 Q-5 Remarks

Raw materials Chemical In appropriate level of Low graded flour Test wheat flour quality. 2 1 2 Yes Yes No Yes Yes PRP
(Wheat flour, moisture and protein of Reject if standards not
Sugar, Soya wheat flour met. Record and inform
flour) receiving supplier
Physical Foreign materials like Container bag, Test in the internal lab 1 1 1 Yes Yes No Yes Yes PRP
cotton thread, broken inappropriate and reject if standards not
piece of stick, stone storage of raw met. Record and inform
piece, iron piece etc. materials supplier
Raw materials Biological Present of insects like Inappropriate Application of pest and 2 1 2 Yes Yes No Yes Yes PRP
Storage flies, rodents, ants etc. application of rodent control activities
pest and rodent by proper monitoring and
control activities keep record. Check pest
control activities by
3 months interval
Chemical Excessive moisture Long time Properly maintain FIFO 2 1 2 Yes Yes No Yes Yes PRP
level storage and FEFO. Keep record
and take necessary steps
if moisture increases
Physical Improper keeping Workers faults Keep record, monitoring 3 1 3 Yes Yes No Yes Yes PRP
quality of bags, violate and concern the
the staking rules responsible person
Water tank Biological Presence of From water tank Properly monitoring 1 3 3 Yes Yes No Yes Yes PRP
microorganism like water tank by 7 days
Colifrom, E- coli etc internal and external test
and microbiological test
Physical Presence of foreign From the water Water quality test e.g.: 1 3 3 Yes Yes No Yes Yes PRP
materials tank iron, arsenic, and
hardness in the internal
lab in every six months
and properly cleaning
water tank by 7 days
interval
(continued)
 Hazard Type Decision tree
Step Name (B,C,P)* Hazard Description Source Control Measure L* S* L  S Qa-1 Q-2 Q-3 Q-4 Q-5 Remarks

Water filtration Biological Presence of From the ground Micro-biological test of 1 3 3 Yes Yes No Yes Yes PRP
microorganism like water water by three months
Colifrom, E-coli etc. interval
Chemical Presence of heavy From the ground Chemical test (arsenic, 3 1 3 Yes Yes No Yes Yes PRP
metal water Iron, Hardness) of water
by six months interval
Physical Presence of foreign From the ground 1 micron filter is used to 1 3 3 Yes Yes No Yes Yes PRP
materials water prevent physical hazards
Wheat flour and Biological Presence of insects like From the flour Reject the flour and keep 2 2 4 Yes Yes No Yes Yes PRP
Soya flour flies, rodents, ants etc. record
sieving Physical Presence of foreign From the flour Magnet use to detect 3 3 9 Yes Yes Yes – – CCP-1
materials like stone, metal and sieving net to
ribbon, broken glass detect other physical
etc. hazards. Reject and keep
record if physical hazards
found more than
acceptable limit
Sugar crushing Physical Presence of foreign From the flour Magnet use to detect 3 3 9 Yes Yes Yes – – CCP-1
materials like stone, metal and sieving net to
ribbon, broken glass detect other physical
etc. hazards. Reject and keep
record if physical hazards
found more than
acceptable limit
Biological Presence of insects like Improperly There is air cutter and 1 3 3 Yes Yes No Yes Yes PRP
flies, rodents, ants etc. netted and the properly netted room
drum is not cover
properly
(continued)
plant
manufacturing
Biscuit

Table II.
 NFS

Table II.
Hazard Type Decision tree
Step Name (B,C,P)* Hazard Description Source Control Measure L* S* L  S Qa-1 Q-2 Q-3 Q-4 Q-5 Remarks

Sugar syrup Physical Foreign materials Improper Concern the responded 2 2 4 Yes Yes No Yes Yes PRP
cleaning of syrup cleaner. Daily monitoring
drum and keep record after
cleaning by the
responsible person
Biological Presence of micro- Excessive Following good hygienic 1 3 3 Yes Yes No Yes Yes PRP
organism e.g. sweating of practices and wearing
Staphylococcus workers hand gloves at processing
area is mandatory
Raw mixing Chemical Variation of chemical Improper weight Properly, weighted and 1 3 3 Yes Yes No Yes Yes PRP
monitored
Physical Contamination with Container bag/ Check like bag condition, 1 3 3 Yes Yes No Yes Yes PRP
jute fiber, plastic sacks and from flour sieving machine and
thread, hair workers hair sugar crushing machine
to prevent foreign
materials and metal.
Wearing caps at
processing area is
mandatory
Biological Presence of insects like Absence/ Good hygienic practice is 1 1 1 Yes Yes No Yes Yes PRP
flies, rodents, ants etc. inappropriate maintained and
application of appropriate application of
pest control pest and rodent control
activities activities in every
3 months
Rotary Molding Physical In appropriate size and Defective molder Expert technician and 2 1 2 Yes Yes No Yes Yes PRP
shape of unbaked enough molder for the
biscuits
(continued)
 Hazard Type Decision tree
Step Name (B,C,P)* Hazard Description Source Control Measure L* S* L  S Qa-1 Q-2 Q-3 Q-4 Q-5 Remarks

immediate solution of this

problem
Baking Biological Microbial growth Improper Monitoring oven 3 3 9 Yes Yes Yes – – CCP-2
monitoring by temperature* and keep
baking man record in every 2 h
interval
Physical Over or under baked Improper Monitoring oven 3 3 9 Yes Yes Yes – – CCP-2
biscuits monitoring by temperature and keeps
baking man record in every 2 h
interval
Cooling Biological Presence of spider net Absence/ Inappropriate application 1 3 3 Yes Yes No Yes Yes PRP
inappropriate of pest and rodent control
application of activities and air cutter
pest control facilities. Active pest
activities control activities by
3 months interval
Physical Dirty condition of Improper Daily monitoring and 2 2 4 Yes Yes No Yes Yes PRP
cooling conveyer belt cleaning of keep record by the
conveyor belt responsible person
Metal detection Physical Presence of heavy From biscuits Metal detectors for 4 3 12 Yes Yes Yes – – CCP-3
metal checking the presence of
heavy metal. Calibrated
metal bar pieces are used
in every 2 h interval and
keep record
(continued)
plant
manufacturing
Biscuit

Table II.
 NFS

Table II.
Hazard Type Decision tree
Step Name (B,C,P)* Hazard Description Source Control Measure L* S* L  S Qa-1 Q-2 Q-3 Q-4 Q-5 Remarks

Collect in striker Biological Presence of spider net Inappropriate Inappropriate application 1 3 3 Yes Yes No Yes Yes PRP
application of of pest and rodent control.
pest control Pest control activities in
activities every 3 months interval
Physical Dirty condition of Irregular and Daily monitoring and 1 3 3 Yes Yes No Yes Yes PRP
striker belt improper keep record after cleaning
cleaning by the responsible person
Packaging and Physical Leakage, improper Lower graded Reject torn cartoon. 2 1 2 Yes Yes No Yes Yes PRP
cartooning taping and weight as cartons and Maintained good hygienic
well as presence of hair improper practices as per standard
packaging procedure
Biological Bacterial growth Due to leakage of Reject the leakage packet 2 2 4 Yes Yes No Yes Yes PRP
packet during checking time
Master carton Physical Leakage, improper Suppliers fault Workers use cap, mask 1 3 3 Yes Yes No Yes Yes PRP
receiving taping and presence of and improper and apron. Reject torn
foreign particles packaging carton during checking
time
Storage and Biological Presence of insects and Absence/ Inappropriate application 1 3 3 Yes Yes No Yes Yes PRP
Dispatch rodents inappropriate of pest and rodent control
application of activities. Active pest
pest control control activities in every
activities 3 months and keep record
Physical Keeping products Irregular By proper training and 1 2 2 Yes Yes No Yes Yes PRP
without pallet and monitoring regular monitoring by the
improper staking rules responsible person

Notes: Quality should be tested as per codex. (B, C, P)* = Biological, Chemical and Physical. *L = Likelihood (Probability): 5 = Frequent e.g. – daily, 4 = Likely
e.g. – weekly, 3 = Occasional e.g.- monthly, 2 = Unlikely e.g.- yearly, 1 = Improbable e.g.- every 10 year. *S = Severity (Consequences): 4 = Very high (catastrophe)
e.g.- death, 3 = High (critical) e.g.- illness, 2 = Medium e.g.- injury, 1 = Minor e.g.- no injuries. aQ = Question. *Temperature range 200-3000 C
3.1 Establishment of pre-requisite programs Biscuit
Legally, PRPs known as the support programs that provide bases for HACCP in whole food manufacturing
safety management program (da Cruz et al., 2006). The conditions and the necessary basic
activities to maintain a hygienic environment for the production, handling and provision of
plant
safe finished products all along the food product process were presented by PRPs (ISO 22000,
2005). From raw materials receiving to final storage and dispatch hazard analysis performed
at every steps to define the biological, chemical and physical factors for ensuring safe
products (Codex, 2009). Severity and likelihood identified the significance of hazard. PRPs
significantly reduced the risk factors that might affect food safety (Table II).
3.1.1 Raw materials receiving. Generally, the biscuit plant used different kinds of raw
materials named wheat flour, soya flour, sugar, salt, vegetable fat, flavor and other leavening
agents. Inappropriate levels of these raw materials significantly affected the quality of biscuit.
It could create distinctive flavor as well as may affect the quality attributes of biscuits including
nutritional level. The industry had a valid supplier evaluation form that meet either national or
international standard. If any of the materials fails to meet the requirements then the rest will
affect during mixing as well as final products. The industries that significantly followed the
valid rules of GMP and HACCP must have to follow the hygienic rules of CODEX general
principles of food hygiene CAC/RCP 1-1969. This significantly reduced the hazard both
chemical and biological. This process also reduced the cross contamination (Table II).
3.1.2 Raw materials storage. Raw materials storage of biscuit plant was maintained
significantly FIFO (First in first out) and FEFO (First entry first out) system. Storage
condition of biscuit plant was free of insects, flies, rodents, ants etc. Appropriate application
of pest and rodent control activities by proper monitoring and keeping record was a vital
issue for food safety. Pest control activities should be maintained in every 3 months. Storage
room were maintained appropriate level of moisture and humidity control system. All raw
materials bag were kept on the pallets and properly followed the staking rules (Table II).
3.1.3 Raw mixing. First of all workers was to follow proper sanitation and hygienic rules
before pouring on the dough mixer machine. Therefore, it was mandatory to wear caps
musk and gloves and practice hand washing periodically for all. Before mixing it was
checked online during sieving that each materials was contamination free from jute fiber,
plastic thread, hair, bags, sacks and other foreign materials. All the raw materials were kept
in dough mixer machine in a sanitary environment. Mixing was fully homogenized and
through maintaining proper time so that no lump left.
3.1.4 Dough forming. After dough forming, operators were taken proper care to prevent
the biological hazard so that contamination cannot be occurred before rotary molding.
Appropriate level of pest and rodent control activities was enough to prevent the biological
hazard present there (Table II).
3.1.5 Rotary molding. In this stage responded ensured that appropriate size and shape of
unbaked biscuits so that the quality of the biscuit is maintained. This stage is a major and
vital issue for quality biscuit and the rest stages will also depended on this stage.
3.1.6 Cooling. During cooling biological and physical hazard might grow. Daily cleaning
monitoring by the responded and appropriate application of pest and rodent control
activities prevent the hazard that may grow in this stage.
3.1.7 Collect in striker. In this stage responded ensured that the cleaner cleaned the
striker properly to prevent biological and physical hazard. Besides appropriate application
of pest and rodent control activities needed in every three months.
3.1.8 Packaging and cartooning. This was another most crucial period in biscuit plant
where no further processing left behind. The process of this stage ensured that no hazard is
present in final product. Care was taken to prevent pathogens from the air so appropriate air
NFS conditioning system was present in packaging room to control temperature and humidity.
Operator ensured that biscuit temperature before packaging was within the acceptable limit
for the prevention of rancidity and ensuring good shelf life. Besides personal hygiene needs
to be carefully checked before enter in the packaging section.

3.2 Establishment of critical control points

After conducting hazard analysis, it was found that generally a biscuit plant contains 3
CCP’s. Critical limit was necessary for processing requirement in every control points
(Table II). HACCP system was applied in this study for ensuring safe biscuit product for the
consumer (Tsui and Morillo, 2016). To prevent the hazard that may create health hazard to
the consumer, operators must have proper training on safe food handling practices
throughout the production process as well as good food hygiene knowledge (Codex, 2009).
3.2.1 CCP-1: sieving before mixing. First CCP suggested in this study was sieving.
Critical limit was Zero (0) here. Generally sieving prevents the biological and physical hazard
(Codex, 2009). Inadequate sieving might allow physical hazard like stone, ribbon, broken
glass etc. These types of physical hazard affected organoleptic quality of biscuits (Table II).
3.2.2 CCP-2: baking. The second CCP found in this study was baking. Baking should be
accurate and appropriate for ensuring proper color and shape of biscuits. As well as baking
significantly reduced the biological and physical hazard (Swanson and Anderson, 2000;
Codex, 2009 and Lima et al., 2017). The critical limit was a vital issue in this stage. In the
present study, critical limit was found from 2000C-2500C (Figure 1). In these stage
thermophile pathogenic bacteria was significantly controlled (Table II).
3.2.3 CCP-3: metal detection. The third and final CCP in this stage was metal detection,
for ensuring the absence of metal in the final product. Heavy metal like Ferrous, Non-
ferrous and Stainless steel generally called heavy metal and after consumption, it could
create significant life threatening disease. Heavy metal free biscuit production was a
challenge for the biscuit manufacturer. Present study suggested that metal detector machine
was must before collection of striker. Critical limit of metal detection suggested in this study
were Fe-1mm, Non-Fe-1.5mm and Finally SS-1.5mm (Table II). This approach significantly
reduced the physical hazard by proper detection and assessment as well as this was an
effective way to advance food safety and quality (Table II) (Codex, 2009).

3.3 Establishing monitoring procedure

A monitoring procedure must be established in the HACCP system to guarantee that the
critical limit established at every CCP could be continuously fulfilled. Object, such as
additive quantity; method, such as demanding for inspection report; frequency, such as
every batch; personnel, such as operators were the following factors for monitoring
procedure contains of HACCP (ISO 22000, 2005; Lu et al., 2014).

3.4 Establishing corrective measures, verification, record and documentation

If there is a deviation from any established CCP, a corrective action must have carried out to
prevent unsafe products from reaching consumers. During this procedure, problems were
corrected and production was put back in control. To determine its safety, any unqualified
products were further tested. A complete HACCP plan also requires a verification procedure,
such as random sampling and testing, to examine whether HACCP could effectively control
food safety (Allata et al., 2017). Moreover, well documentation was used for implementation of
the HACCP system. The content of hazard analysis, CCP determination, and recordkeeping
includes CCP monitoring activities. Deviation, associated corrective actions and verifications
were usually includes in documentation. These procedures supports to validate that HACCP Biscuit
controls were in place and were being correctly maintained (ISO 22000, 2005; Lu et al., 2014). manufacturing
plant
3.5 Establishing the documentation and record keeping
Various documentation models were used in this study for monitoring selected measures
control and ensuring appropriate corrective actions. To provide evidence of effective
implementation of the system, documentation and records was established (Lu et al., 2014).
The operational documents were divided into two groups: general procedures and detailed
instructions (Dzwolak and Zuraw, 2003; ISO 22000, 2005).
This study identifies the significant hazard that could affect public health. HACCP is
such an approach that dramatically reduced the sufferings and can create a system which is
a structured form and ensure food safety from farm to fork. In this system, raw materials
supplier evaluation was a vital fact. Monitoring the responsibility of the farmer capturing
their performance was also included. However, the system was monitored from primary to
final production by systematic monitoring which was a vital issue for food safety. Regular
systematic monitoring attached with this system. Only CCP alone was not all. CCP’s reduces
huge sufferings but PRP’s declares overall process was running in a controlled way (Lu
et al., 2014). Documentation and records generated in the HACCP system could easily help
tracing the contamination (Allata et al, 2017). This system also helped to prevent cross
contamination. Finally, it was declared that this system provides higher quality, hygiene
standards and ensures better quality biscuit product (Table II).

4. Conclusion
The hazards in biscuits production are mainly attributable for the use of inappropriate
processing conditions, and unsanitary manufacturing environment. The results of this study
showed the extent of the positive effects that a HACCP system introduced in a biscuits factory
had on both the microbiological quality of the final product and on the total quality/hygiene
management. The application of the HACCP system provides food manufacturers with
effective preventive methods to guarantee food safety and improve management. Additionally,
the documentation and records generated in the HACCP system can easily help in tracing the
origin of contamination, thus preventing further production of substandard products and lower
the consumption of manpower, material and financial resources. At present, HACCP is difficult
to implement in some manufacturing plants because of technical and financial obstacles.
Although most of the major manufacturers have applied HACCP for biscuits production, the
problems come from the point of sale. Therefore, this measure requires government support for
its wider application. Further linkage of the HACCP system introduced in the factory for
quality management systems, such as International Organization for Standardization
regulation, can be possibly proved to provide higher quality/hygiene standards, along with
higher awareness among the customers (i.e. biscuits retailers).

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Corresponding author
Suvasish Das Shuvo can be contacted at: suvasish.shuvo@yahoo.com

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