HALALAN TOYYIBAN AND HAZARD ANALYSIS (ISH 553)

CASE STUDY:

NUTRI FOOD : BEEF PATTY

NAME OF LECTURER:

DR. FARHANI BT ZARMANI

PREPARED BY:

NO. MEMBERS NAME MATRIC NO.

1 NURHAZIQAH BINTI JOHAR 2020957393

2 NUR FARAH HANIS BINTI RAMLI 2020958929

3 ATIFAH NATASYA BINTI ROSMAWI 2020984549

4 NUR SYAHIRAH BINTI BAHARUDDIN 2020959495

5 SITI NURUL WAHIDAH BINTI YUSOF 2020987673

6 MOHAMMAD HIDAYAAT BIN NORDIN 2020973603

HACCP INTRODUCTION

There is now a growing concern in the population about food. Progressively, what
individuals eat is of almost significance, particularly in aspects identified with wellbeing and
nutrition.
Many of the diseases currently influencing the general population, for example,
cardiovascular illness, osteoporosis, diabetes or certain tumours, are caused or connected with
the food we eat, considerably lessening buyer confidence in relation to sanitation. At the
same time, the consumer’s thoughtfulness regarding sanitation and quality has expanded. The
cases of bovine spongiform encephalopathy (BSE) contagious to people (Creutzfeldt-Jakob
infection), the use of hormones in the production of meat, the use of antibiotics as creature
development favourable to promoters, the pesticide build-ups in plants and animals, the
presence of nitrates in the waters, the doubts related with the genetically modified the forms
markets, or cases of avian influenza in humans, decreased purchaser confidence with respect
to the safety of food (Moura, 2008). On the other hand, the major risk in food creation is
microbiological tainting (Jeng, 2003).
HACCP is a comprehensive prevention method that uses common sense in the
interpretation of scientific concepts. The most critical feature of HACCP is that it is a
prevention method rather than an inspection system for monitoring food safety hazards.
Danger avoidance cannot be done by means of a product review but monitoring the
manufacturing process through HACCP provides the best possible solution. The deployment
of the HACCP is systematic, as standardised hazard analysis and implementation are given.
The method has common sense in that each processor knows their procedure and is better
able to analyse the process control. HACCP is also science-oriented and so the controls put in
place should be based on scientific information.
The HACCP teamwork has two main components. HACCP’s HA is a logic in the
hazard analysis that describes when and how hazards exist. The CCP is a vital control point
providing control of the mechanism and evidence of control. The final goal of HACCP is to
make the substance as safe as possible and to be able to show that the product has been
handled as efficiently as possible. Safety assurance is focused on the method of recognizing
threats, developing safeguards for established hazards, tracking controls and frequent
verification of the operation of the system.
COMPANY PROFILE / COMPANY BACKGROUND

1. Company Name Nutri Frozen Food Sdn. Bhd

2. Business Address No. 41, 43 & 47, Jalan 31/10A, Taman

Perindustrian IKS, 68100 Mukim Batu, Batu
Caves, Selangor Darul Ehsan, Malaysia

3. No. Telephone 03-6185 8355

4. E-mail [email protected]

5. Website https://nutrifrozen.com/

6. Mission Our main mission is to make traditional products

such as dim sum and various cakes a common
food practice for all Malaysian consumers of
various cultures and races. All Nutri Frozen Food
Sdn Bhd products have halal status and we will
ensure that all Malaysians can enjoy the variety of
traditional foods that we offer.

7. Vision Ready to offer traditional halal food to all people

of various races without doubting the halal status
and hygiene.
ORGANISATION CHART
FOOD SAFETY AND MANAGEMENT POLICIES

To ensure products achieve high quality and safe to be consumed by customers and try to
maintain food levels are always in good condition and achieve halal status at all times
because most products are frozen and baked products. Therefore, product safety level is
highly emphasised. All Nutri Frozen products meet the safety standards in the Halal
certification system, comply with Hazard Analysis Critical Control Point (HACCP), ISO,
GMP and MESTI standards.

COMPANY MISSION AND VISION

Mission :

Our main mission is to make traditional products such as dim sum and various cakes a
common food practice for all Malaysian consumers of various cultures and races. All Nutri
Frozen Food Sdn Bhd products have halal status and we will ensure that all Malaysians can
enjoy the variety of traditional foods that we offer.

Vision :

Ready to offer traditional halal food to all people of various races without doubting the halal
status and hygiene
PLANT LAYOUT
HACCP TEAM AND RESPONSIBILITIES

No. Position Job Description

1. CEO ● Main person responsible for document control, including

the overseeing of the development, review and
maintenance of all quality and food safety systems,
including: HACCP, procedures, methods, recipes, work
instructions, specifications and records.
● Responsible for the development, training and safety of
all food handling personnel.

2. Production Manager ● Management of the product

● Product elaboration

3. Quality Control/ ● Identify hazard in the product

Assurance ● Implementation of sanitary and hygiene conditions
during production and packing of products.
● Conduct internal audit as per schedule
● Checking of daily reports for further improvement
and taking corrective action if necessary.
● Coordination with third parties like labs,
certification, regulatory authorities etc.
● Internal verification of day to day activities
● Responsible for product quality & safety and for
maintaining the hygiene conditions.
● Develop, recommend and monitor corrective and
preventive measures.

4. Haccp Expert ● Professional consultations from consultant company

concerning on HACCP system

5. Microbiologist ● Quality control of raw material and final product

● Hygienic stage of the equipments
● Determines the critical control points in the process flow
based on the contamination level.
 ● Writes procedures for hygiene practice in the unit

6. Maintenance Manager ● Verify technical stage of the equipment and sanitary

performance of equipment
● Construction materials for production spaces and storage
● Ventilation equipments and the efficiency of drain
system
FOOD SAFETY OBJECTIVE

The main reason for implementing the HACCP system in our products is to ensure our
products are safe for customers to consume. Therefore, our company also already set up the
following food objectives to be achieved and maintained for next 1 year.

1. To ensure all products are free from any hazards and safe for consumers to use.
2. To apply the value of hygiene in the environment to make sure the food is produced
under hygienic conditions and it is not hazardous to human health.
3. To overcome any harm that occurs by identifying the microorganisms that will appear
later.
4. To minimise the likelihood of contamination of pathogenic microbes and to reduce
their potential for growth and development.
PRODUCT DESCRIPTION

Product Name Beef Patty

Ingredients Beef meat, Textured vegetable protein, Modified tapioca

starch, salt, spice, sauce, sugar

Brand Nutri Frozen Food

Important product Perishable

characteristics

Storage Purchase the product before “sell-by” or expiration dates.

Keep beef patties in its packaging until just before using.
To keep the meat in high quality, store in the refrigerator for
7 days and freezer for 1-2 months.

Shelf life Between 3-6 months from date of manufacture

Packaging type Vacuum packaging and Modified atmosphere packaging

(MAP)

Labelling instruction Keep frozen at -18 celsius. Do not refreeze once thawed.
for consumer Consume within 5 days of opening.

Special Distribution Keep frozen

control

Where product will be Retail, wholesale, food service and hypermarket

sold

Sensitive ingredient No allergen

and allergen

Process type reworked -

materials (if any)

Traceability code Date of manufacturing (dd/mm/yy) and production code

BEEF PATTY FLOWCHART PROCESS STEP

M- Microbiological
P- Physical
C- Chemical
 HAZARD ANALYSIS FOR RAW MATERIAL/ PACKAGING MATERIAL

Q1 Q2 Q3 Q4 Q5 Q6

Raw Potential Hazard Rationale for What Measures can be Is this raw material/packaging
Material/ inclusion or applied to control the material a sensitive material?
State whether Is this a Significant Hazard?
exclusion as a significant hazard? (Yes/No)
Packaging biological, chemical, Hazard
Material or physical

Severity Likelihood Significant Yes/No Q1 Q2 Q3 Yes/No

Yes/No Yes/No Yes/No

70% meat Biological : Inclusion : 2 A 3 Yes -Workers practice good Yes Yes Yes Yes
Pathogenic bacteria hygiene and join the food
such as Campylobacter Bacterial growth handling training.
jejuni , Campylobacter will occur on raw
coli ,C. botulinum and meat due to -Monitor temperature
C. perfringens and environmental when a shipment is
Salmonella factors, improper received and should be
handling methods, kept at temperatures
temperature abuse below 4˚C .
and growing at
prolonged cooling
temperatures
 Chemical : Animal Exclusion : 5 D 24 No -Obtain from reliable Yes Yes No No
drug residues and supplier and request COA
heavy metal Residue
certification
presented for live
animals from
supplier

-Maintain adequate
Physical : sand and Inclusion : 3 B 9 Yes sanitation while receiving Yes Yes Yes Yes
plastic Contamination of and do inspection every
stored packing batch
materials and
supplies from
foreign material

TVP Biological: Exclusion: 4 C 18 No -Practice personal hygiene No No Yes Yes

(textured Staphylococcus spp, among employees
vegetable Bacillus spp They have low
protein) bacteria counts and
difficult for bacteria
to multiply

Exclusion : -Must get confirmation

Chemical: 2 C 8 No from the supplier that No No Yes Yes
contamination by less potential and material safe to use
pesticide residues, rare found on
mycotoxins materials
 Physical:Harmful Exclusion: 4 D 21 Yes -Perform a physical Yes No Yes Yes
materials such as glass, examination
metal, plastic and wool Through several
processes and less
discovered

MTS Biological: Exclusion: 2 C 8 No -Practice the cleanliness

(modified of the surrounding
tapioca Staphylococcus aureus, the material is dry
starch) Bacillus cereus, and suitable for all
Listeria temperature
monocytogenes,
Escherichia
coli,Salmonella
enterica
- - - - - - - - -
Chemical: N/A
-

Exclude: 3 C 13 Yes
Physical:
-Externally inspect the
The foreign objects can Rarely found in material
be found material
-Isolate the damaged
 Biological: N/A - - - - - - - - - -

Sauce
Chemical: N/A - - - - - - - - - -

Physical: Exclusion: 3 D 17 No Receive from reliable No No No No

supplier
Foreign matter may be Rarely be found
found such as insects

Biological: N/A - - - - - - - - - -

Salt

Chemical: Exclusion : All 5 D 24 No Purchasing from a Yes Yes No No

contamination from items are visually recognised source, and
non-food chemicals, inspected as they obtaining a certificate
such as non-food are processed to from the supplier proving
grade, and guarantee that no that they are free of
contamination from an foreign material is pesticides and heavy
overabundance of food present. metals.
additives

Physical: presence of Exclusion : rarely 4 D 21 No - visual examination of Yes Yes No No

hazardous extraneous found incoming raw materials
material (inspection report)

Insect, fragment, hair - strict adherence to first

 etc in, first out

- quality assurance
guaranteed

Spice Biological: Exclusion: 2 E 16 No - Control Measure plan Yes Yes No No

powder from the supplier
Salmonella, E. Coli,
Clostridium The suppliers - Ingredients purchased
perfringens, implement control under a letter of
Staphylococcus aureus, measures on raw guarantee.
Bacillus cereus, materials.
Aspergillus,Penicillium
spp.

Chemical: pesticides, Exclusion: 2 D 12 No Ingredients purchased Yes Yes No No

fertilizers under a letter of
Some guarantee. The supplier
microorganisms are has a record that is
often considered regulated.
naturally occurring.

Physical: glass, wood Exclusion: 4 E 23 No Ingredients purchased No No No No

or any foreign material under a letter of
(American Spice Trade The supplier was guarantee. They may be
Association) prepared a list of included as part of GMP.
equipment capable
of removing the
physical impurities
 that can
contaminate raw
materials.

Sugar Biological : presence Exclusion : reliable 5 E 25 No Certified supplier Yes Yes No No

of pathogenic bacteria supplier
e.g.: salmonella spp. In
halva, tahini

Chemical : Presence Exclusion : 5 E 25 No A certificate from the Yes Yes No No

of Mycotoxins and a Purchasing from supplier to prove that
presence of undeclared Approved supplier, there are free from
allergens could impact chemical substance
on sensitive individuals

Physical : presence of Exclusion : rarely 4 D 21 No - Inspection report Yes Yes No No

hazardous extraneous found
material - Strictly maintained first
in first out
Any foreign materials
- Quality assurance
(canadian food assured
inspection agency,
2008)
 HAZARD ANALYSIS FOR PROCESS STEP

Process Potential Rationale for inclusion or What Measures can be

Step Hazard exclusion as a Hazard Is this a Significant Hazard applied to control this Is this process step a Critical
(1) State whether (3) (4) significant hazard? Control Point?
biological, (5) (Yes/No)
chemical, or (6)
physical
(2)
Severity Likeli Signific Yes/ Q1 Q2 Q3 Q4 Yes/No
hood ant No

Receiving Biological : Inclusion : -Hygiene practises of food

Salmonella , -Bacterial contamination during handlers before and after Yes Yes Yes Yes Yes
Staphylococcus the handling process from the 2 A 3 Yes processing meat.
aureus slaughterhouse -Maintaining temperature below 3
-During transportation due to ° C.
irregular temperatures -Isolation of raw and dried
-Mixing with other materials products when receiving materials
from transport trucks.

Chemical : N/A - - - - - - - - - - -

Physical : wood , Exclusion : -Control with Certificate of

metal, rubber, Unlikely to occur because the raw 3 D 17 No Analysis (COA) No - - - No
plastic material is well packaged -Visual inspection for foreign
material.

Weighing Biological: Inclusion : Inadequate temperature -Control the temperature and g

Clostridium control in the room environment 2 B 5 Yes maintain a clean environment. Yes Yes Yes Yes Yes
botulinum, Listeria cause the growth of bacteria and -Proper equipment cleaning
 monocytogenes unsanitized equipment

Chemical :
antioxidant, Inclusion : Excessive addition of Control the quantity of additives
antimicrobial agent restricted ingredient 2 B 5 Yes safely and follow the rules as Yes Yes Yes Yes Yes
, curing agent and labeled.
tenderizing agents .

Physical : N/A
-
- - - - - - - - - -

Grinding Biological: Inclusion: Temperature abuse and 4 C 18 Yes Control the time and temperature Yes Yes Yes Yes Yes
and thawing Presence of an unsanitized environment may because those are also the most
pathogens: cause bacterial growth. Grinding is important factors permitting
Salmonella, done rapidly enough to prevent growth of bacteria.
Listeria pathogen growth.
monocytogenes,
Staphylococcus
aureus,
Clostridium
perfringens,
Clostridium
botulinum; E.coli.

Chemical: Pre-op SSOP makes the presence 2 C 8 Yes Proper equipment cleaning. Yes No No No No
Cleaning or of chemical residues unlikely to
sanitizing chemical occur.
residues
 Physical: Metal Visual observation for foreign 2 C 8 Yes Always maintain good hygiene Yes No No No No
materials during processing, practice
inspection of equipment during
cleaning make hazards unlikely.

Mixing with Biological: N/A - - - - - - - - - - -

additive
Chemical: Inclusion: Incorrect amounts may 2 B 4 Yes Addition of defined amount of Yes No Yes No Yes
Excessive of cause nitrite poisoning. nitrite per mix
sodium nitrite

Physical: N/A - - - - - - - - - - -

Patty Biological: Inclusion: Inadequate temperature 2 C 8 Yes -Control the minimum and Yes No No No No
formation Presence of control in the room environment maximum of the temperature
bacteria such as cause the growth of bacteria and -Visual examination
Escherichia coli unsanitized equipment -Always maintain good hygiene
and Lactobacillus practice
spp.

Chemical: N/A - - - - - - - - - - -

Physical: Exclusion: Rarely to be found 3 C 13 No -Maintain good hygiene practice Yes No No No No

-Presence of and good manufacturing practice
workers jewellery -Periodic cleaning
and dirt

Packing Biological: Inclusion: Temperature abuse and 3 B 9 Yes -Maintain good manufacturing Yes No Yes Yes Yes
Presence of unsanitized environment may practice and good hygiene
bacteria such as cause bacterial growth. practice.
Escherichia coli -Fast moving
and Lactobacillus
spp.

Chemical: N/A - - - - - - - - - - -
 Physical: Exclusion: 3 D 17 No -Visual examination Yes No No No No
-Presence of -Pre-requisite program -Metal detector inspection
foreign metal -Rarely to be found -GMP and GHP practice
-Presence of insect
and dust

Freezing Biological : Inclusion : 2 A 3 Yes Freezing area must be clean and Yes Yes Yes Yes Yes
Growth of -pathogen development at low under 30°C for 45 minutes
pathogen temperatures and pollution

- Abuse of temperature may result

in pathogen proliferation.

- Unsanitary handling

Chemical : N/A - - - - - - - - - - -

Physical : Metal Metal fragment from conveyor 4 A 3 Yes Metal detection is a process step - - - - -
Fragment may stick to product that is specifically intended to
remove metal contamination.

Storage Biological : It is unlikely to occur since the 2 A 3 Yes Keep track of the storage Yes Yes Yes Yes Yes
Microbial growth storage temperature is regulated temperature and shelf life.
and a GMP programme is in place
to avoid contamination.

Chemical : N/A - - - - - - - - - - -

Physical : Pest and Inclusion : pests may infiltrate the 4 3 12 Yes Manage the storage area properly Yes Yes Yes Yes Yes
dust storage space and contaminate the and install pest control
goods.
 HACCP PLAN SUMMARY

CCP No. & Significant Critical Limits Monitoring Corrective Verification Records
Process step hazard Action

What How Frequency Who

CCP 1 Biological : Freezer Temperature Reading Everyday Production Personnel Product and Temperature
Freezing Growth of temperature from officer product testing ambient log or record
pathogenic under 30°C freezer determines temperatures are sheet.
bacteria such as temperature whether to keep monitored on a
Salmonella spp gauge or reject a daily basis by
etc. product. designated
personnel.

CCP 2 Biological : Cold room Temperature Monitored Everyday Production -Environmental Twice Weekly -In a plant
Storage Microbial growth temperature ≤ regularly officer and internal visual review of storage or
22°C temperatures are temperature data maintenance
checked twice by an individual journal, note
daily by who did not all outcomes
individuals in generate the and remedial
charge of the records but has action(s), as
function using successfully well as the
predefined completed a date and time
activities. HACCP course of of
training, or by the observation.
-Sign, date, and responsible
record the time of establishment -Log of
observation for official Corrective
all discoveries in Actions
the HACCP
storage log.
 CCP 3 Biological: -At 41°C or Temperature -Maintainin Every Production -Any food items -Supervisor Temperature
Grinding and pathogen bacteria below in the ga single hour. officer. that have begun the visually observes log or record
thawing growth refrigerator. temperature thawing process that employees are sheet
for proper that must be thawing food
cooked within 72
-Under potable thawing properly and that
hours.
running water corrective actions
that is at or -Ensure -If a refrigerator is are taken when
below 70°C product not maintaining needed.
immediatel 41°C or below, and
y cooked if the product was -Temperature will
after out of temperature be checked with a
thawing in for a verifiable stem thermometer.
the time of less than 4
microwave hours then move
the product to a
unit properly
maintaining 41°C
or below.

-If the product

temperature was
above 41°C for an
unverifiable time
or longer than 4
hours then discard
the product.

-Food not cooked

immediately after
thawing in the
microwave is
discarded.
VERIFICATION ACTIVITIES

Activity Minimum Frequency

● Verification the scheduling ● Annual

● Pre-requisite program verification ● Initially, annual thereafter

● Validation of critical limits and ● Before and during HACCP plan

HACCP plan implementation

● Revalidation of HACCP plan ● Annual or upon significant change

● Observation and interview of CCP ● Quarterly/monito/CCP

monitor

● CCP monitoring record review ● Daily

● Equipment calibration ● According to HACCP plan

● Other record review ● Monthly

● HACCP system verification ● Annual

SUMMARY OF PRE-REQUISITE PROGRAM

1) Good Manufacturing Practice (GMP)

Good manufacturing practises (GMP) are the procedures that must be followed in
order to comply with the rules established by the agencies that oversee the permission
and licencing of the manufacture and sale of food, as well as any other schemes.
These rules provide basic requirements that a company must achieve in order to
ensure that their goods and outputs are of consistent high quality from batch to batch.

The sequence that governs each industry may differ noticeably. However, the major
purpose of GMP is always to avoid anything bad, like injury, from happening to the
customer or end user. GMP stands for Good Manufacturing Practises, and it is a
system that ensures the effectiveness of a quality management system.

2) Good Hygiene Practice

Personal hygiene is the most crucial aspect to consider since it will aid in the
maintenance of physical and mental health and hygiene. This approach was
previously established in the Food Act of 1983 and the Food Regulations of 2009.
This will guarantee that all personnel in the manufacturing follow all of the
instructions provided and will avoid any contamination of the completed products.

3) Sanitation Standard Operating Procedure (SSOP)

SSOPs are often written procedures that must be followed to guarantee that product
contact and non-product surfaces are appropriately cleaned. These cleaning
techniques must be rigorous enough to ensure that no product adulteration occurs. All
HACCP plans need SSOPs to be reported and evaluated on a regular basis in order to
make physical plant changes. This review approach can take many forms, from annual
formal reviews to random evaluations, but "responsible" should be employed for all
reviews.

4) Pest Control

Pests are carriers of illness, dirt, and germs, and all of these hazardous
microorganisms may be easily passed to foods, causing contamination and spoilage.
As a result, the cost of replacing defective food and food on a regular basis will be
included.
CONCLUSION

To summarise, HACCP is a good programme that has been used to minimise and reduce food
safety danger mishaps. Recognizable proof of hazards and the application of corrective
improvements may be implemented quickly by tracking and identifying prospective concerns
throughout the full cycle and procedure. The HACCP system ensures that the environment in
which goods are manufactured is safe. This will boost worker morale since they will be
working in a clean atmosphere where all food safety rules are followed. This might motivate
employees to stay focused and perform a better job. One of the primary benefits of HACCP is
that the consistency of the food produced is superior to that of food produced without any
HACCP guidelines. Higher-quality items will make more buyers happy, which implies
greater benefits for us. HACCP also enables enterprises to adapt approaches for anticipation
and discovery to their application, allowing them to implement new systems and innovations
effectively and without issue. HACCP adoption may give several major benefits in addition
to improving the food safety system.

HACCP certification confirms that the corporation is adhering to all HACCP criteria
and recommendations. This improves the brand's image and attracts more customers. Because
the FDA is recognised internationally, the items will be accessible for sale to other countries,
increasing foreign trade. This will continue to increase customer interest in food safety. As
we all know, customers want nutritious and tasty foods to help the food business thrive and
flourish on a global scale. Our organisation has produced a safe-to-eat beef patty by utilising
HACCP to limit the danger of hazards. All processes in our organisation follow the standard
operating procedure of the HACCP system, which is particularly successful in producing
safe-to-eat beef products. Last but not least, the presence of a HACCP system in our
organisation will boost consumer trust in purchasing our goods.
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