“Year of the Strengthening of National Sovereignty”

PRODUCTION OF ELDERBERRY JAM

F A C U L T Y ENGINEERING

Course

Gestión de Calidad

Teacher

Perla Krystell Paredes Concepción

STUDENTS:

Alminagorda Gala, Reida

Zuñiga Fernandez, Thalia Stephanie

Fernandez Davila Seminario, Sebastian

2022
INTRODUCTION 3

OBJECTIVE 3

QUALITY CONCEPTS AND TECHNICAL STANDARDIZATION 3

Product standard 3
Scope 3
Definitions 4
Requirements 4
Test methods 4
Packaging and storage requirements 5
Procedure standard 5
Scope 5
Definition 5
Procedure 5
Critical incidents 6

QUALITY SYSTEM AND EXCELLENCE MODELS 6

Regulation of the process 6
Raw materials 7
Equipment and utensils 7
Facilities 7
Hygiene 7
Operations 7
Control of production processes 7
The EFQM Excellence Model 8

STATISTICAL QUALITY CONTROL 9

Acceptance Sampling 9
Systems to achieve food safety 9

SURVEILLANCE SYSTEM OF CRITICAL CONTROL POINTS (CCP) 10

CCP 1: Closed 10
CCP 2: Heat treatment 10

REFERENCES 10
INTRODUCTION

Wild berry jam is the most popular and valuable product of the processing of berries such as
blueberries, raspberries, strawberries, blackberries, the production technology of which
involves the use of a pectin solution to form the necessary gelatinous consistency, which, in
turn, It is accompanied by an increase in production costs and the complication of the
manufacturing process.

In recent years, Peru has experienced rapid growth in the agricultural sector, offering a wide
variety of export products such as organic bananas, mangoes, grapes, etc. However, there are
products in which there is no greater commercial use, which leads farmers to lose interest in
their cultivation, consequently, the devaluation of the fruit, this product is the elderberry.

In the present work we will give a quality approach to organize and control the productive
processes of the food industry, controlling operations, inputs, material and human resources
necessary for the production plans. Taking into account the parameters of a product according
to standards, to ensure the quality of the product in the market, concepts of quality and
technical standardization will be used. Then apply tools to improve quality. Finally,
regulations and integrated quality systems such as ISO 9001 will be carried out.

OBJECTIVE

● Application of the knowledge of the course to improve the quality of a food product.
● Establish an efficient quality assurance system that guarantees safety in the Elderberry Jam
production line.
● Identify biological, chemical and physical hazards, establishing preventive controls and
criteria to guarantee control, monitoring critical control points and recording data.

QUALITY CONCEPTS AND TECHNICAL STANDARDIZATION

Product standard

TITLE: Elderberry Jam

Scope

The scope of this standard is to establish the requirements that must be met by the elder fruit intended
for fresh consumption or as raw material for jam processing.
 Definitions

a. Elderberry jam is a product with a gelatinous consistency, red wine in color and with a
sweet-sour taste, obtained by cooking or absorption.
b. Elderberry jam is the concentration of healthy fruits, properly prepared, with the addition of
sweeteners, with or without the addition of water.

Requirements

Dimensions:
Height 12.50 c.m
Width 7 c.m
Weight 400 g

Sensory Characteristics
Shape rigid
Consistency Pasty and uniform
Appearance bright
Colour intense purple and red
Flavour characteristic elderberry

Physical characteristics
_Its texture must be viscous, which is due to the presence of pectic substances and its
appearance must not be transparent.
Chemical characteristics

● Soluble solids per reading (°Brix) at 20°C: minimum 64%, maximum 68%
● pH: 3.25 – 3.75
● Ethyl alcohol content in %(V/V) at 15°C/15°C: maximum 0.5
● Preservative: Sodium Benzoate and/or Potassium Sorbate (alone or together) eng/100
ml. : maximum 0.05

Test methods

Test method for determination of Elderberry Jam:

Cooking method:

● Large hermetically sealed metal vessels are used that work at vacuum pressures
between 700 to 740 mm Hg.
 ● It is carried out at atmospheric pressure where the product is concentrated at
temperatures between 60 and 70 °C, preserving better the organoleptic characteristics
of the fruit.

Packaging and storage requirements

Packaging

The jam containers will be placed in a box with cardboard partitions, each one covered with
bubble wrap in order to avoid cracks when they collide with each other.

Storage

The jam in glass jars "healthy" and properly sterilized.

Procedure standard

TITLE: Elderberry Jam

Scope

The scope of this standard is to define the way in which the Quality Management System of
the company's operations details and justifies all the procedures that are carried out.

Definition

a. The manufacturing standards are criteria related to the way in which they must be
manufactured.

b. Provisions through which the work is carried out, as well as the fulfillment of the
obligations of the manufacturing procedure.

Procedure

Write a draft of the steps in a clear and concise way, but also make sure to include enough
detail so the person performing the task can carry it out correctly.

1. Reception and weighing. In this operation, the fruits were separated by their level of
maturity.
 2. Washing and disinfection. It was done in order to remove soil residues or foreign
particles present in the fruits and minimize the microbial load present in the fruit rind.
3. Party, pulped and sieved. It consists of subtracting the juice from the elderberry.
4. Heavy. The fruit is weighed.
5. Evaporation and concentration. It is subjected to heating and evaporation. The
proportion of sugar was incorporated at the beginning of the heating of the mixture
6. Cooled. It is stored at ambient temperatures.
7. Packaging and Sealing.
8. Stored

Critical incidents

Write critical incidents: What situations should no be presented

1. Prolonged cooking (hydrolysis of the pectin) causing a jam without firmness.

2. Crystallization caused by a high amount of sugar in the preparation.

3. Excessive humidity in storage or contamination prior to the closing of the containers

causes the growth of fungi and yeasts on the surface of the jam.

QUALITY SYSTEM AND EXCELLENCE MODELS

Regulation of the process

Reference will be made to the regulations given by the National Agricultural Health Service
and the regulations mentioned in the CODEX standards for jams, jellies and jams. Likewise,
some requirements will be provided that must be followed in the production process of
elderberry jam so that the production line works in an adequate way. Technical Standards:

Within the industrial processes, Good Manufacturing Practices or GMP must be taken into
account , which will be summarized as:

Raw materials

Raw materials or ingredients containing parasites, undesirable microorganisms, traces

of pesticides, drugs or toxins, foreign decomposed substances that could not be
reduced to acceptable levels should not be accepted.
Equipment and utensils

They must be designed and used in such a way as to avoid contamination of food and
facilitate its cleaning, easy maintenance, of non-absorbent materials, nor corrosive, resistant
to repeated cleaning and disinfection operations, nor must they transfer to the product toxic
material or substances, odors or strange tastes.

Facilities

The surroundings of the facilities must be protected to prevent the entry of contamination
such as dust, insects and other animals. Production facilities must have adequate spaces for
the unloading of raw material, weighed and for the processing of fruit.

Hygiene

A hygiene process must be followed for the development of operations, in addition to

having clean toilets provided with soap, toilet paper and adequate ventilation.

Operations

All food manufacturing processes must be carried out in optimal sanitary conditions,
following the established procedures, which must be documented in flowcharts
including all unit operations of the process.

Control of production processes

The control sheets and process record allow to give credibility and effectiveness to
the quality control system and safety of the final product.

Regarding the finished product, codex stan 296-2009 will be followed, codex
standard for jams, jellies and jams:

● The amount of fruit used as an ingredient in the finished product shall not be
less than 35%.
● Have a suitable gelatinous consistency.
● Color and flavor appropriate for the type or class of fruit used as an
ingredient in the preparation of the mixture.
● The product must be free of defective materials normally associated with
fruits.
● The product must be free from the presence of plant matter such as peel or skin
 The EFQM Excellence Model

Model Criteria Characteristic

Ensure that the organization's quality management system is developed and

Leadership
implemented to achieve short and long term success in fulfilling the mission and vision.

Develops and updates company policies and strategies through a framework of key
Strategy
processes related to research, learning and creativity.

Identify the capabilities of the people working in the organization, enhance their
People
knowledge by planning activities to support their individual growth.

Partnership and Management of strategic alliances for the benefit of the organization to enhance the
Resources operation of processes.

Processes, Product
Plan and innovate the necessary process improvements to meet customer needs.
and Services

Excellent organizations holistically achieve outstanding results with respect to their

Results customers, people, and society, including measures related to social, environmental, and
economic performance.

Systems to achieve food safety

ISO 9001
Our company's policy when making elderberry jam is to meet our standards and make a good product
for consumers. We garantized the quality of the product and always looked for more standards
and worked in a secure mode.

● Control any cross contamination, ensure the production of any product for the safety of
consumers. This involves each type of contamination, considering the reception of the
raw materials until the distribution of the batch.
● Train our workers in their roles and responsibilities, regarding the importance of quality
and safety of manufactured products.
● We involve all company personnel in the Quality Management System, Food Safety and
Food Defense in the development of safe and quality products.
● We improve our facilities and our production systems, thus ensuring continuous improvement
of the production system.
 Plan-Do-Check-Act Cycle

1. Plan: Recognize an opportunity and plan a change.

2. Do: Test the change. Carry out a small-scale study.
3. Check: Review the test, analyze the results, and identify what you’ve learned.

4. Act: Take action based on what you learned in the study step. If the change did not work, go
through the cycle again with a different plan. If you were successful, incorporate what you
learned from the test into wider changes. Use what you learned to plan new improvements,
beginning the cycle again.

The analysis of the hazards involved in the preparation of the elderberry jam was carried out following
a format in which all the potential hazards are detailed, including the justification and the preventive
measure associated with them, in order to minimize the risk to health. of the end consumer.

Identify
significant food Preventive measure to prevent
Identify Hazards Justification
safety hazards significant danger
(YES / NO)

● Train staff in the use of

● Poor control of warehouse stocks
Physical: warehouse records
can cause a misapplication of the
Presence of foreign ● Training of personnel in hazard
YES PEP`s principle.
matter (dust, etc.) control and good manufacturing
● Deterioration of the product due to
practices.
breakage of the container.

● Alterations caused by insects

Microbiological:
Pest infestation of
formerly stored lots.
Contamination of the
product by pathogens.
and rodents can occur in the
● Apply sanitation programs.
warehouse.
● Confirm the identity of the
YES ● When storage conditions
product.
(temperature) are poor, it
contributes to the development
of mold.
SURVEILLANCE SYSTEM OF CRITICAL CONTROL POINTS (CCP)

CCP 1: Closed

The intention is to visualize the sequence of steps to provide the service, in a closed system
and thus examine in which phases the greatest dangers occur, what are the preventive
measures and where the critical control points are located. It should be added that each
institution has to develop the flow chart according to the characteristics of the service it
provides.

CCP 2: Heat treatment

In order for the CCP to be identified, a surveillance system has been established “Planned
sequence of observations and measurements of Critical Limits designed to ensure total control
of the process”; The monitoring system must allow any deviation to be detected in time so
that the critical limits are violated and thus ensure process control. The monitoring results are
records as evidence of its execution and for traceability. Any observation, incident during
surveillance must be reported in the same record and communicated to the immediate
superior. The storage tank with a cold system is the property of the client, the maintenance of
the cold system and calibration of the tank temperature control thermometer is the
responsibility of the client, who performs it annually through the calibration services
company.

Process Control

Flow chart
The cause and effect diagram

Elderberry jam production control chart

Control Chart X - R
Control Chart C
STATISTICAL QUALITY CONTROL

Acceptance Sampling

Taking into account the sampling plans (n,c), these data have been provided by the elderberry
jam samples. It is required to obtain the OC curve.

𝑆𝑎𝑚𝑝𝑙𝑒 𝑠𝑖𝑧𝑒 (𝑛 = 100)

𝐴𝑐𝑐𝑒𝑝𝑡𝑎𝑛𝑐𝑒 𝑛𝑢𝑚𝑏𝑒𝑟 (𝑐 ) = 1
 ADVANCED TOOLS TO IMPROVE QUALITY

HACCP
1. Form a HACCP Team

In the implementation of the HACCP system, it will be determined that the work team provides
general knowledge. Necessary knowledge regarding food safety, such as: Physical, Chemical,
Biological hazards and associated with the production process.

Sufficient experience with regard to the production process will be analyzed, in which it will be
determined:

● What to do
● How it should be done at all times

Sufficient skills about the principles for their correct application.

FUNCTION FUNCTION DESCRIPTION NAMES AND CHARGE

SURNAMES

HACCP SYSTEM Is responsible for the entire quality management Ing. Thalia Haccp system executor
EXECUTOR system

HEAD OF QUALITY He is responsible for the HACCP plan, its correct Ing. Reida Head of quality
MANAGEMENT application, verification, validation and any management
changes directly related to the process.

QUALITY Reports to the head of quality management, who is Quality assurance

ASSURANCE in charge of recording, monitoring the processes Cristina technician
TECHNICIAN analyzing the corrective actions

ONLINE It is responsible for production operations and Ing. Sebastian Online production
PRODUCTION coordinates with the HACCP system executor. supervisor
SUPERVISOR
MAINTENANCE It is responsible for the application and verification Denis Maintenance manager
MANAGER of the maintenance program and in this way
achieves in optimal conditions the operation within
the production.

2. Describe the Product

Next, the organoleptic characteristics of the product, physical description, physicochemical
characteristics, shelf life, potential consumers, packaging are described.

HACCP PLAN OF ELDERBERRY JAM

PRODUCT NAME Elderberry Jam

ORGANOLEPTIC ● Shape rigid

CHARACTERISTICS ● Consistency pasty and uniform
● Appearance bright
● Color intense purple and red
● Flavour characteristic elderberry

PHYSICAL DESCRIPTION Pasty consistency

PHYSICOCHEMICAL ● Soluble solids per reading (°Brix) at 6.5°C: minimum 64%, maximum 68%
CHARACTERISTICS ● pH: 3.25 – 3.75
● Ethyl alcohol content in %(V/V) at 15°C/15°C: maximum 0.5

SHELF LIFE 12 months in a cool, dry environment

POTENTIAL CONSUMERS All public

PACKAGING Glass container 240 g

STANDARD: Regulations STANDARD FOR JAMS, JELLIES AND JAMS

3. Describe the Use to which the Product is to be Destined

The intended use of elderberry jam has a wide range of consumers without age restrictions and people
suffering from diabetes, leukemia, providing benefits to their health, due to the characteristics of the
product, characterized as a plus that differentiates it from other types of jams.

4. Create a flowchart of the process

 5. Check the Flowchart.

When developing elderberry jam it is required to comply with the following processes, such as:

1. Reception and inspection: The fruit of the elderberry, pectin, glucose is received and an
inspection is carried out on the raw material to proceed with the respective selection.
2. Selection: In this operation, those fruits in a state of rot, fruits that have not reached their state
of maturity are eliminated, bunches and external agents from the place of production are also
eliminated.
3. Washing and disinfecting: It is done in order to eliminate any type of foreign particles, dirt
and remains of earth that may be adhered to the fruit. This operation is performed by
immersion, agitation and sprinkling. Once washed the fruit is immersed in a disinfectant
solution. The disinfectant solution is composed of sodium hypochlorite (bleach) in a
concentration of 0.05 to 0.2%. The immersion time in these disinfectant solutions is 8
minutes. Finally, the elderberries are rinsed with plenty of water.
4. Heavy: The respective weighing is carried out in a capacity balance of 200 kg and is weighed
in buckets of capacity of 25 kg each. This process is important to determine the yield and
calculate the amount of the other ingredients that will be added later.
5. Pasteurized: The elderberries are pasteurized in stainless steel pots with a capacity of 50 kg
gently for this you have 2 high pressure cookers at a temperature of 65 ° C for a period of 10
minutes.
 6. Filtering: In this process the corresponding filtering is done which consists of separating the
whole fruits of elderberry and the elderberry juice for this a mesh and buckets are used, the
corresponding weights are recorded this allows to calculate the weights of the inputs since
20% of the juice is destined to obtain dye which is stored in hermetic tanks.
7. Heavy: In this process the corresponding weights of both the juice and the whole fruit of
previously pasteurized elderberry are recorded.
8. Formulation: At this stage the corresponding calculations are made according to the total
weight of the whole elderberry fruits and the respective juice and the weights are calculated
according to the formulation: the formulation is as follows: total weight of elderberry: 100%
elderberry juice intended for coloring: 20% pasteurized whole elderberry fruit: 60%
elderberry juice: 20% sugar: 75% pectin: 1% citric acid: 0.05% preservative: 0.05%
9. Cooking: This cooking process is important to break the cell membranes of the elderberry
fruits and extract all the pectin, to prevent it from burning 20% of the respective juice is used.
The cooking time is 3 hours and at a temperature of 95 ° c. Addition of sugar and citric acid
once the product is in the process of cooking and the volume has been reduced by a third, we
proceed to add the citric acid and half of the sugar directly then until it dissolves after 1 hour
the total amount of remaining sugar is added. Adding the preservative once the gelling point
is reached, the preservative is added. This should be diluted with a minimum amount of water.
Once it is fully dissolved, it is added directly. The percentage of preservative to be added
should not exceed 0.05% this process is of vital importance since the quality department
controls under formats.
10. Transfer: Once the final point of cooking is reached, the jam is removed from the pot and a
skimmer is introduced to eliminate the foam formed on the surface of the jam. Immediately
afterwards, the jam is transferred to another container in order to avoid overcooking, which
can cause darkening and crystallization of the jam. The transfer will allow the jam to cool
slightly, which will favor the next stage that is the packaging
11. Packaging: It is made hot at a temperature not lower than 85°C. This temperature improves
the fluidity of the product during filling and at the same time allows the formation of an
adequate vacuum inside the container due to the effect of the contraction of the jam once it
has cooled. In this process, a pitcher with a beak is used to easily fill the containers,
preventing it from spilling over the edges. At the time of packaging it is verified that the
containers are not cracked, or deformed, and are clean, disinfected and sterilized. The filling
is carried out to the level of the container, the lid is immediately placed and the container is
turned over in order to sterilize the lid.
12. Cooling:The packaged product must be cooled quickly to preserve its quality and ensure the
formation of vacuum inside the container.
13. Labeling: Labeling is the final stage of the jam making process. All information about the
product is included on the label.
14. Stored: the product is stored in a cool, clean and dry refrigeration chamber; with sufficient
ventilation which guarantees the conservation of the product until the moment of its
commercialization for which the finished product manager is responsible.

Basic principles of HACCP

6. Identify Hazards Determine the Critical Control Points
The hazard analysis is based on determining all the dangers that are involved in the process of making
elderberry jam, that is why each and every one of the stages of the process are analyzed, in which the
Biological, Chemical, and Physical factors are involved that can harm the quality of the finished
product and endanger the health of consume
OPERATION HAZARD IDENTIFICATION THERE ARE JUSTIFY YOUR DECISION FOR COLUMN 2 WHAT PREVENTIVE MEASURE CAN BE THIS IS A CRITICAL
DANGERS APPLIED TO PREVENT SIGNIFICANT POINT OF CONTROL
JUSTIFYING DANGER (YES/NO)
YOUR DECISION
FOR FOOD
SAFETY (YES/NO)

Physical ● Poor handling during post-harvest and ● Evaluation and selection of suppliers.
● Presence of foreign particles in the transport. ● Sensory control at the reception.
elderberry batch. yes ● Poor conditions in the supplier's storage. ● Sampling during reception to identify
● Lack of weight. ● Poor conditions of transport of the raw physical hazards.
● Presence of pests in the elderberry material. ● Certificate or protocol of analysis.
(rodents, ants, etc.). ● Lack of control in the heavy. ● Evaluation and selection of suppliers.
Chemical RISK: (MEDIUM) ● Vehicles equipped for transport.
● Pesticide contamination yes SEVERITY: (MEDIUM) ● Proper conditioning of the storage area.
● Contamination with lubricants
● Aflatoxin contamination yes ● The presence of traces of pesticides and Staff training in: PCC
Microbiological lubricant residues can alter the sensory yes
● Contamination by Aspergillus characteristics of the product. ● Use of technical sheets, for the
Reception
Flavus, Bacillus cereus and other ● For lack of control in the warehouse. reception of raw material.
and molds in grains. ● Poor post-harvest management. ● Quality control of raw materials and
inspection ● Presence of pathogenic bacteria, RISK: (HIGH) safety.
mesophilic aerobes. Fecal coliforms SEVERITY: (HIGH) ● Visual and organoleptic inspection of
and fungi. ● Poor post-harvest handling and high the product
● Presence of pests (rats, cockroaches, humidity in the storage area.
etc.) ● Deficient BPA practices can cause
cross-contamination and the subsequent
development of microorganisms.
RISK: (HIGH)
SEVERITY: (HIGH)

Physical
Presence of remains of pebbles and dust.
Chemical
● Presence of remains of metals,
plastics from transport containers.
yes ● Lack of training of operators during the ● Comply with the instructions and
selection of raw material. training of the operators.
yes ● Lack of cleaning and maintenance of used ● Perform a review of the raw material
utensils. after being received to rule out the
yes presence of foreign agents. PCC
 ● Presence of systemic pesticides that ● Improper storage of raw material in ● Application of use controls on NO
Selection are still present in the fruit. unconditioned environments. pesticides, such as the planning of talks.
Microbiological ● Cross-contamination caused by processes.
● Contamination with viable aerobic ● Lack of the correct application of good
mesophiles, bacillus cereus, manufacturing practices.
coliforms and molds.

Physical yes ● Deficiency in the hygiene of the staff and ● Preventive maintenance of utensils and
● Presence of foreign objects such as neglect of these during the selection used materials.
stones, plastics and others. yes process. ● Good manufacturing practices and
Presence of metals due to the ● Lack of care during the dosage of hygiene and sanitation plan.
wear of the materials of the yes chlorinated water. ● Compliance with work instructions.
Washing and receiving containers. ● Poor PHS practice and staff carelessness. ● Comply with good storage practices.
Chemical ● Lack of control of the raw material. ● Realization of a good dosage of
disinfecting ●Residues of detergents and PCC
● Mishandling of stored batches. chlorinated water.
disinfectants and presence of ●Inadequate handling and poor hygiene of YES
pesticides in elderberries. washing and storage utensils, deficiency in
Microbiological the cleanliness of the area.
●Contamination by pathogenic
microorganisms by
cross-contamination.

Physical yes ●Improper handling of materials and ● Compliance with THE BPMs by the PCC
Heavy ●Presence of foreign particles (hairs, equipment. plant operators. NO
plastics, etc.) yes ●The personnel are not trained in the proper ● Verify the calibration of the equipment
Chemical handling of the instruments. before weighing.
● Chemical contamination by detergent yes ●Improper cleaning of utensils and materials ● Control the hygiene of the staff.
residues (chlorine). used in the weighing can cause ● Control of operator parameters.
Microbiological cross-contamination and the subsequent
● Microbial contamination by proliferation of microorganisms.
pathogenic bacteria. ●Poor calibration of heavy equipment.

Physical yes ●Improper handling of materials and ● Compliance with the BPMs by the plant
●Presence of foreign particles (hairs). equipment. operators.
Chemical yes ●The personnel when they are not trained in ● Verify the parameters and optimal
●Chemical contamination by chemical the proper handling of the pasteurization conditions of the raw material during PCC
inputs. yes equipment can ignore the parameters pasteurization. YES
Microbiological required for this process which is a crucial ● Control of operational parameters.
Pasteurized ● Microbial contamination by point in the processing. ● This process reduces the presence of
pathogenic bacteria. ●Improper cleaning of the materials used in pathogenic microorganisms by the use
pasteurization, this can cause crusada of temperature and therefore adequate
contamination. care and control must be given.

Physical yes ● Improper handling of materials and ● Control the hygiene of the staff.
Filtering ●Presence of foreign particles (pieces of equipment. ● Verify that the equipment is clean and
fruit stems, etc.) yes ● Improper cleaning of utensils and materials give it proper maintenance before
Chemical used in pasteurization and filtering, this can processing. PCC
●Chemical contamination by chemical yes cause cross-contamination and the ● Control of operational parameters. NO
inputs. subsequent proliferation of
Microbiological microorganisms.
● Microbial contamination by
pathogenic bacteria.

Physical yes ● Compliance with good manufacturing

Formulation ●Contamination with foreign matter by ● Presence of impurities in the environment of practices in environments.
the environment no the formulation process. ● Comply with the pre-operational and
Chemical ● A heavy deficiency causes heterogeneity in operational cleaning and sanitation PCC
●None yes the product. program. NO
Microbiological ● Poor hygiene practices and disinfection of ● Verification of the labels of the minor
●Contamination with microbial equipment and utensils can cause inputs before making the fish.
pathogenic bacteria. contamination of the product. ● Perform and verify that heavy
equipment is well calibrated.

Physical yes ● Improper cleaning of utensils and materials ● Compliance with good manufacturing
Cooking ● Presence of foreign particles used in cooking, this can cause practices in environments..
Chemical No cross-contamination and the subsequent ● Verification of the labels of the minor PCC
●.None proliferation of microorganisms. inputs before making the fish. NO
Microbiological yes ● A heavy deficiency causes heterogeneity in ● This process reduces the presence of
●Contamination with microbial the product. pathogenic microorganisms by the use
pathogenic bacteria. ● Poor hygiene practices and disinfection of of temperature and therefore adequate
equipment and utensils can cause care and control must be given.
contamination of the product.
 Physical
● Presence of foreign particles.
Microbiological
Packaging ● Contamination of the product by the
packaging.
● Microbial contamination due to poor
sealing of the final product.
yes ● Loss of tightness of the packaged product
due to defective sealing.
● The lack of weight causes fraud in the
product.
yes ● Habits of poor hygiene, causes that the
product can become contaminated with
pathogenic bacteria.
● Training of personnel in hazard control
and good manufacturing practices.
● Train staff in corrective actions of the PCC
packaging process. YES
● Organize the movement of the product.

Physical ● Poor warehouse control can lead to a

●Presence of foreign matter.
Microbiological
Stored ●Pest infestation of stored lots.
●Contamination of the product by
pathogens.
misapplication of the PEPS principle.
yes ● Deterioration of the product due to
breakage of the container.
yes ● Alterations by insects and rodents may
occur in storage.
●Train staff in the use of warehouse
records. PCC
●Training of personnel in hazard control YES
and good manufacturing practices.
●Implement sanitation programs.
●Confirm product identification.
7. Determine the Critical Control Points

8. Establish validated critical limits for each CCP

Critical limits are established as parameters that must be achieved and controlled as a preventive
measure in a way that guarantees the safety and innocuousness of the product.

Critical Limits

● Reception and inspection: In this operation, an inspection and verification of the product
must be carried out.
● Washing and disinfecting: It was set as a limit of chlorine concentration should be between
2 and 3 (ppm)
● Pasteurized: Pasteurized at high pressure and at a temperature of 65°C for a period of 10
minutes
● Packaging: This operation must be carried out when the product is at a temperature between
70 and 60 ° C, covered correctly and immediately and then subjected to cooling by means of
cold water jets whose action will help the conservation of the product.
 ● Storage: It was established that the limits for the storage of the product are between 20 and
25 °C.

9. Establish a Monitoring System for Each CCP

To achieve an adequate surveillance system, it is determined in each of the Critical Control Points
(CCP) defined in the process of making elderberry jam with the following surveillance stages:
What to monitor? The characteristics of the product or process shall be verified to determine the
conformity of the product.

How to monitor? It deals with the surveillance procedure through observations.

Monitoring frequency? The frequency will be carried out after having determined the possible risks.

Who will monitor? There must be a responsible person to carry out the respective surveillance,
but above all have the knowledge to apply the corrective measures.

When is it monitored? The moment will be defined whenever necessary, being in continuous time,
providing information in real time.

10. Establish corrective actions

Corrective actions are those that will be taken if a deviation is detected or if the critical limits are out
of control, in the process of making elderberry jam that must be oriented to improve the process,
before the diversion to the place avoiding the loss of food security. Corrective measures are used to:

● Identify potential hazards

● Correct and eliminate the cause of the danger
● Verify the elaboration process
 Process stages/ pcc Critical limit What How Frequency Who Corrective action

Pcc 1 Maximum 10 hours Time control Checking and Every time the The person in charge of ● Download and upload management.
Reception and from harvest to inspecting each load of shipment of material receiving raw materials ● Merchandise quality control.
inspection product delivery material comes in.

2ppm and 3 concentration By formula Once for 2 Operator ● Low concentration. Adjust the
ppm of chlorine in math of minutes concentration and perform the wash again.
Pcc2 Chlorine water washed. determination of ● Very high concentration, wash with plain
Washing and concentration water, if the opposite occurs, if the
disinfecting objective is not met, discard.
● Keep record.

T ≥65°C t ≥10 pasteurization using equipment Continuous (every 10 Operator ● If the temperature drops below the critical
Pcc3 Pasteurized minutes temperature measurement of seconds) limit, the diverter valve opens.
vapor 6% temperature.

Pcc4 It is set to The using equipment every 5 minutes Operator ● Set a strict control of the conditions of
Packaging maximum 70°C and temperature of measurement of during packaging cooling.
minimum 60°C product temperature. ● Perform an analysis to determine that the
product keeps the characteristics of safety.
● Keep record.

Pcc5 Control of temperature Installing visible 2 turns by Supervisor ● Adjust the thermometer until the ambient
Storage storage and area equipment course of the day. of the area. temperature and humidity are reached.
between 20 and 25 C humidity temperature ● Keep record
storage. measurement and
humidity.
 11. Establish a Verification System

PCC REGISTRATION RESPONSIBL VERIFICATION

E

RECEPTION Product quality and supervisor ● Review and sign the formats of the
AND condition material
INSPECTION

WASHING AND Chlorine concentration for supervisor ● Review chlorine concentrations

DISINFECTING washing elderberries ● Results of corrective actions

Monitoring log. CCP Plant operator ● Review of monitoring records and

PASTEURIZED “Pasteurization” corrective actions. Frequency: daily.
● Review of calibration records of
monitoring instruments.

PACKAGING Temperature control for jam Plant operator ● Vacuum temperature control
packaging ● Results of corrective actions

STORAGE Temperature control for the Plant operator ● Calibration of the humidity meter
storage area of finished ● Temperature result
products

12. Establish Documentation and Record Keeping

A Documentation system will be established in which each of the procedures related to the inherent
principles established by the HACCP system is registered.

QFD and FMEA

Process Potential Potential Severity Potential Frequency Detectability RPN=S

Stage failure mode effects of of causes of of of failure (D)
failure failure failure occurrence
effect (O)
(S)

Low quality Poor 5 Poor 2 2 20

Reception and elderberry flavor supplier
inspection jam program

Low quality Spoiled 4 Poor 1 2 8

Selection elderberry jam supplier
program

Undisin Bacterial 8 BPM 2 2 32

Washing and fected fruit contamin
disinfecting ation
 High Thick 6 Tempera 2 3 36
Pasteurized temperature jam ture
control

equipment poor 6 lack of 2 2 24

Cooking hygiene quality maintena
product nce

sloppy inadequa 4 poor 2 2 16

Packaging Packaging te boxes training

a lot of few 5 poor 2 3 30

Cooling product elderberri training
es

large number effect 5 poor 1 2 10

Labeling of containers products training
with product

high rejection 6 poor 1 2 12

Storage temperature by quality maintena
ol control nce

REGULATIONS AND INTEGRATED SYSTEMS OF QUALITY

Design of experiments and Taguchi methods
Evaluation of stability of anthocyanins in the pulp base of elder (Sambucus peruviana) during
the storage at different pHs and temperatures.
According to the investigation, an experimental design was applied with a 3x3 factorial arrangement
with 3 repetitions, evaluating the stability during storage at different pHs and temperatures of the base
pulp of Elderberry (Sambucus peruviana) during 30 interday days, whose formula is shown below and
the matrix of the experimental design of Completely Random Blocks.
 Integrated management systems IMS ISO 9001+14001+HACCP
● Quality Management
Advice and support in the process of implementation and certification in integral management
systems, such as ISO9001, ISO14001, and quality standards, such as BPA, GMP and Ecological.
Quality assurance in all phases of the project and product. In order to be able to offer our customers
suitable solutions that meet their individual needs, resulting in a high degree of satisfaction.
ISO 9001 Quality Standard
Certification according to ISO 9001, is the confirmation of the high quality standard of our products
and services, the successful interaction of processes and continuous improvements and optimizations
to these processes are essential basic requirements of this quality standard.
● Environmental Management
Environmental certification according to ISO 14001 and ISO 22000. The company must be certified
according to ISO 14001 and ISO 22000. The constant work of environmental and energy management
ensures that our products, systems and processes are continuously being improved with regard to
environmental protection and careful use of resources.
● Commercial management:
Advice and support in the commercial promotion of companies through the generation of information
on markets and commercial spaces such as business roundtables and fairs.
● Innovation Management:
Advisory service in improvement of products, processes, packaging and labels. Accompaniment in the
formulation and management of innovation projects.

Mandatory document ISO 9001 ISO 14001 ISO 22000 This comment
 4.3 4.3 4.3 Once the scope is defined, all activities,
The scope of the quality products and services of the organization
management system that fall within this scope are included in
the environmental management system.

4.4 4.4 4.4 The document is in the same clause in the

Quality management system three ISO, in this the processes and
and its processes procedures are required for the planning
and execution of the product.

5.2 5.2 5.2 The clause guides us that customer service,

punctuality in departures and arrivals of
The quality policy products and the knowledge and skills of
our staff are key elements for the
improvement of our processes.

6.2 6.2 6.2 The clauses of the different ISOs are

Quality objectives specific business goals for the value and
performance of our products or services.

Maintenance and Calibration 7.1.5.1 9.1 7.1 The clauses ensure the correct functioning
of the equipment and measuring
instruments of all the operations that are
established.

Traceability of measurements 7.1.5.1 The clause is only presented in ISO 9001

which consists of a documented chain of
measurement standards or measurement
procedure in the realization of the product

Competences 7.2 7.2 7.2 The clauses are presented in all the ISOs
that guide us to carry out a study of
competitors.

Control of documented 7.5.3 7.5.3 7.5 The clause is presented in all the ISOs that
information guide us to make a control of documented
information.

Planning and operational 8.1 8.1 8.1 We find the clauses of the documents or
control requirements in the three standards which
will guide us for the same purpose.

Determination of requirements 8.2.2 8.2 We find the clauses of the documents or

for products and services requirements in 2 of the standards that
indicate the guide that will take into
account both.

Review of product or service 8.2.3 8.3 Important in both standards for the product
requirements

Design and development input 8.3.3 8.4 Important requirements in both standards
data for the product

Controls in the design 8.3.4 8.4 Important requirements in both standards

for the product
Design and development output 8.3.5 Important clause for a product standard
data

Design and development 8.3.6 8.5 Important requirements in both standards

changes for the product

Supplier Evaluation 8.4.1 Important clause for a product standard

Characteristics of the product 8.5.1 Important clause for a product standard

or service

Identification and traceability 8.5.2 Important clause for a product standard

Changes in Customer Property 8.5.3 Important clause for a product standard

Changes for production or 8.5.6 Important clause for a product standard

service provision

Release of products and 8.6 8.6 Important requirements in both standards

services for the product

Control of non-compliant 8.7.2 - 8.9 Important requirements in both standards

outputs 10.2.2 for the product

Monitoring, measurements, 9.1.1 9.1 9.1 Very important clause requirements in the
analysis and evaluation three standards for the product

Internal audits 9.2.2 9.2 9-2 Very important clause requirements in the
three standards for the product

Departures from management 9.3 9.3 9.3 Very important clause requirements in the
review three standards for the product

Nonconformities and corrective 10.2.2 10.2 10.1 Very important clause requirements in the
actions three standards for the product

QUALITY AUDIT (Falta)

GROUP (Activity, Impacts (Effect on the

Description Aspects (Cause)
Product, Service) Environment)
Activity Reception Water Usage Depletion of Natural Resources

Waste generation and

Activity Selection Degradation of human health and
disposal
air quality
Washing and
Activity disinfecting Waste of water Depletion of natural resources
Activity Heavy Energy Usage Depletion of natural resources
Activity Pasteurized Generation of waste Contamination
Spills of Chemical
Activity Filtering Usage Degradation of human health
Activity Heavy Energy Usage Depletion of natural resources
Activity Formulation Chemical Usage Depletion of natural resources
Activity Cooking Waste of water Depletion of natural resources
Degradation of human health and
Activity Transfer Energy usage
Depletion of natural resources
Activity Packaging Energy usage Depletion of natural resources
Activity Cooled Energy usage Depletion of energy
Activity Labeling Energy usage Depletion of natural resources
Degradation of human health and
Activity Stored Energy usage
Depletion of natural resources

HACCP PLAN AUDIT CHECKLIST

Date of Audit Audit File No:

Company being audited Jams and Jelly CO

Address Calle las Mermeladas 251

Reviewer …

Phone Fax +1 1234567

Contact contactojam@industry.com

Products Jam and jelly

Company Sebastian Fernandez Davila, Thalia Zuñiga and Reida Alminagorda

Representatives

No. of Employees 10

Technical Resources Yes

REQUIREMENTS RESULTS/COMMENTS

HACCP TEAM

Has a HACCP Coordinator been appointed? Yes

Has a HACCP Team been selected? Team selected

What are the skills and experience of the team The team has been selected with d
and are they appropriate?

Are external resources being used to augment Yes, external quality and safety capacitations
knowledge of skills?

– composition Sugar, elderberry, additives

– packaging (inner/outer) Glass jar with bubble wrap in a cardboard box

– method of preservation Pasteurization and storage far from the light

– distribution conditions Cardboards are going to protect the jar so could

be moved everywhere

Has the intended use been specified? Yes, food

– consumers (general, specific) People in general

– sensitive populations (aged, children, sick, Diabetes

allergenic)

Has a flow diagram been prepared for each Each product has their own diagram
product?

Is the flow diagram complete? Yes

– all unit operations included? Yes

– major inputs identified? Yes, sugar and elderberry

Has the flow diagram been verified? Yes, during the process
When?

PRINCIPLE 1 - HAZARD ANALYSIS

Have all reasonable biological, chemical or Yes, and had been identified with the PPC
physical hazards being identified at each step?

Have the hazards been assessed for Yes have been identified
significance?

Have control measures been developed and Yes, the quality control unity have the
implemented for the control of those hazards? parameters to control it

REQUIREMENTS RESULTS/COMMENTS

PRINCIPLE 2 - CRITICAL CONTROL

POINTS

Have the Critical Control Points for each Each CCP have been identified
significant hazard been identified and
transferred to the Hazard Audit Table?
Are they essential for the control of the Yes
nominated hazard?

Have Work Instructions been completed for Yes

each Critical Control Point?

PRINCIPLE 3 - CRITICAL LIMITS

Have critical limits been established for each Yes all the preventive measures are defined
preventative measure?

Is the relationship between the hazard and the Yes

critical limit correct?

How were the limits determined? Depend of the effect on the product

– experimental evidence? Yes, microbiological

– published results? Yes, the liberation of the product

PRINCIPLE 4 - MONITORING
PROCEDURES

Do the monitoring procedures specify what, Yes each part is indicated

when, how, where and who?

Is the frequency of monitoring sufficient to Yes each process has a quality control process
provide a high level of assurance that the
process is under control?

Are monitoring records kept and reviewed by Yes, each day they check the control quality
the appropriate personnel? format

Have examples of monitoring forms been Control Quality process control - Format
provided in the manual?

PRINCIPLE 5 - CORRECTIVE ACTION

Have corrective actions been developed for each Yes, each CCP has a possible corrective action
critical control point?

Do the corrective actions ensure that the CCP is Yes, the microbiological part
brought under control?

Do the corrective actions cover product, process Yes, assuring the quality and safety of the
and prevention of recurrence? product

REQUIREMENTS RESULTS/COMMENTS

PRINCIPLE 6 - VERIFICATION
PROCEDURES
Have verification procedures been put in place Yes
to demonstrate that the HACCP program is
effective?

Have the critical limits been validated? Yes

Do the verification activities demonstrate that Yes

the CCPs are under control?

Do verification activities demonstrate that the Yes

HACCP program is effective?

PRINCIPLE 7 - RECORD KEEPING

Have records been maintained for all monitoring Yes, different formats
procedures?

Have all critical limits been adhered to? Yes

Have records been maintained for all corrective Yes

actions?

Have records been maintained of all HACCP Yes

verification activities?

DOCUMENTATION

Is there a Quality Manual? Yes

Quality Policy? Yes

Procedures, work instruction forms and Yes and also they enforced with capacitations
specifications identified?

Are all referenced documents controlled? Yes

GOOD MANUFACTURING PRACTICE

(GMP)

Has a GMP policy been defined? Yes

Is there a system for auditing the GMP? Yes

Is corrective action taken in response to Good Yes

Manufacturing Practice nonconformance?

Is GMP being practiced? Yes, in every process

CLEANING PROCEDURES

Have cleaning procedures been developed? Yes

REQUIREMENTS RESULTS/COMMENTS

Have verification procedures for effective Yes

cleaning been developed and implemented?

Is corrective action documented? Yes, each cleaning has a record

PEST CONTROL

Have pest control procedures been developed Yes

and documented?

Is there a verification procedure for effective Yes

pest control?

Does the procedure include corrective action? Yes

TRAINING

Are there records of training? Yes, each month a different capacitation

Are training needs reviewed on a regular basis? Yes

Is there a training plan to provide identified Yes

training needs?

CALIBRATION

Has the calibration status of measuring Yes

equipment been identified?

Are there documented procedures for Yes a record of the maintenance

calibration?

Are there procedures for reviewing material Yes

produced while equipment was out of
calibration?

PRODUCT IDENTIFICATION

Have procedures for product identification been Yes

developed and documented?

Is "heldout" product identified? Yes, the raw material and the product

Overall Comments: All the HACCP process is defined and applicable

Audited by: Ing. Reida Date: XX-XX-XXXX

Accepted by: Ing. Sebastian Date: XX-XX-XXXX

REFERENCES
FAO. (2020) . Norma para las confituras, jaleas y mermeladas.
https://www.fao.org/fao-who-codexalimentarius/sh-proxy/en/?lnk=1&url=https%253A%252F
%252Fworkspace.fao.org%252Fsites%252Fcodex%252FStandards%252FCXS%2B296-2009%
252FCXS_296s.pdf

NORMA GENERAL DEL CODEX PARA ZUMOS (JUGOS) Y NÉCTARES DE FRUTAS. (2014).
Disponible en: http://www.codexalimentarius.neUgsfaonline/groups/details.html?id=1O

Norma Técnica Peruana. (2009). Instituto Nacional de Defensa del Consumidor y de la Propiedad
Privada Intelectual. NTP para néctares. Lima.