INTERNATIONAL DEVELOPMENT AND INVESTMENT CORPORATION IDI FRESH FISH FACTORY No1 WORKSHOP I Factory...

INTERNATIONAL DEVELOPMENT AND INVESTMENT CORPORATION

IDI FRESH FISH FACTORY No1 WORKSHOP IFactory add: Vam Cong IP., Binh Thanh Village, Lap

Vo Dist., Dong Thap province, Vietnam Tel: 067 680 383 Fax: 067 680 382 Website: www.idiseafood.com

Doc code: HACCP I

Date of issue:

30/09/2011

Period of issue: 02

Amendment: 01

APPENDIX1.Appendix…………………………………………………………………………………………………………………………1

2. Productdescription…………………………………………………………………………………...............2

3. Processing diagram…………………………………………………………………………..……………….……..4

4. Technology process………………………………………………………………………..………….……….…….5

5. Risk analysis………….…………………………………..........................................................8

6. General table of CCP……………................................................................... 14

6. General table of HACCP………………….……………………………………....................……..15

7. Prompt error correction-file record –HACCP……..……………………………..……20

8. Implementation of HACCP……………………..………….…………………………………............21

1

9. Investigation of HACCP staff……………………………….……………………………………........22



Vo Dist., Dong Thap Province, Vietnam Tel: 067 680 383 Fax: 067 680 382 Website: www.idiseafood.com

Doc code: HACCP I

Date of issue:

30/09/2011

Period of issue: 02

Amendment: 01

PRODUCT DESCRIPTIONProduct name: Tra fish – Frozen Basa fillet

No CHARACTERISTICS DESCRIPTION1 Product - Basa fish- Frozen Tra fillet

2 Raw material - Basa fish :Pangasius bocourti.- Tra fish :Pangasius hypophthamus.

3 Exploiting area

- Farming areas in floating cages are undercontrol of competent organs of An GiangProvince, Dong Thap Province, Vinh LongProvince, and Can Tho City. Farestdistance from the farms to theCorporation is about 150 km.

4 Preservation, transportation and receipt of raw

- Farms in floating cages and ponds will beunder control of competent organs in caseof sales contract signed with the

2

materials

factory. QC or purchasing staff of thefactory come to take samples understandard requirements in terms of qualityin accordance with standard of thefactory No TC/01/CN. Only ponds and cagessatisfying the standards of will bepurchased.

- Living fish are transported to the fishport of the factory by well-boats. Then,they will be put in the plastic tank andmoved to the raw material receiving areaby trucks. Here, QC staff will eliminatefish that do not meet the requirementsstipulated in the sales contract. Afterthat, fish are weighed and conveyed tothe factory for the implementation of thenext.

5 Summary of finished product specification

Fillet fish are colored and graded:60-120 ; 120-170 ; 170-220;220-UP…(gr/piece), 4-6 ; 6-8 ;8-10 ;10-UP …(OZ/piece) (under customers’ requirements )- Block freezing: 4,5 or 5.0 kg/block, the

same size and species (under customers’requirements ).

- IQF freezing :0,9 hay 1 kg /PE, the samesize and species (under customers’requirements )

- Glazing (10% or 15% under customers’requirements )

Note: PE bag can only be sealed whensufficient information in line with labelrequirements is provided.

6 Others - Salt, phosphate

7 Summary of processing stage

Receiving Bleeding -Cleaning 1 Filleting Cleaning 2 – SkinningoffTrimming Parasite checking Sizing, Cleaning 3 Addictive treatinggrading Weighing - Cleaning 4 Tray-arranging Cool storage Freezing Trayoff - Glazing - Refreezing Weighing ,PE/PA packing Mental detecting Packing Preservation

3

Note: if frozen by IQF, tray-laying and trayoff do not exist.

8 Packing design

- Block freezing: putting 2 fish block of4.5 or 5.0 kg of the same size in thecarton.

- IQF freezing: putting 10 or 12 PE bags(0,9 or 1,0 kg) under customers’requirements, of the same size and gradein the carton.

9 Preservation condition - Preserving in the cold store at the temperature ≤ -200C

10Conditions of product distribution and transportation

- Products are distributed, transported in a frozen state and preserved at the temperature ≤ -200C .

11 Time of usage - Within 24 months from the date of production

12Time for selling in markets and supermarket

- No

13 Requirements for labels

- Product name, size, grade, weight, dateof production, time of use, instructions,preservation condition, manufacturername, Vietnamese farmed products,enterprise code, product lot code

14 Other requirements andspecial conditions - No

15 Goal for usage - Well-cooking before eating16 Subject for usage - All people

17Strict regulations andrequirements

- 28 branch standards 117:1998 and standards of imported countries ( not lower than Vietnamese standards)

Dated September 30, 2011 Approved by:

4




Doc code: HACCP I

Date of issue:

30/09/2011

Period of issue: 02

Amendment: 01

PROCESSING DIAGRAMTra fish- Frozen Basa Fillet

GMP1.1

Water GMP1.2

By-products Cold water

GMP1.3

Water +ice GMP1.4

GMP1.5

Cold water

GMP1.6

Addictive chemicalWater + cold waterGMP1.7

5

TRIMMING

PARASITE CHECKING

CLEANING 2, SKINNING OFF

BLEEDING, CLEANING 1FILLETING

RECEIVING RAW MATERIALWeighing 1

ADDICTIVE TREATING

SIZING, CLEANING 3

GMP1.8

Cold water

GMP1.9

BLOCK FREEZINGIQF FREEZING

GGGGGGGGGGG GMP1.10

GMP1.11

GMP1. 11 GMP1.12

GMP1.12GMP1.13 GMP1.14

GMP1.13

GMP1.14 GMP1.15

GMP1.15

Dated September 30, 2011

6

COLORING

WEIGHING 2, CLEANING 4

TRAY-LAYING COLD STORAGE

COLD STORAGE FREEZING

GLAZING- REFREEZING

WEIGHING 3 –PE WRAPPING–MENTAL DETECTING- PACKINGTRAY OFF/ PE WRAPPING

MENTAL DETECTING/PACKING

PRESERVATION

PRESERVATION

FREEZING

Approved by




Doc code: HACCP I

Date of issue:

30/09/2011

Period of issue: 02

Amendment: 01

PROCESSING TECHNOLOGY

STAGE TECHNICALPARAMETER

DESCRIPTION

Receivingraw

materials,weighing 1

- Minimumweight400g/fish.- Meeting thestandard ofthe company NoTC/01/CN

- Farms in floating cages and ponds will beunder control of competent organs in caseof sales contract signed with the factory.QC or purchasing staff of the factory cometo take samples under standardrequirements in terms of quality inaccordance with standard of the factory NoTC/01/CN. Only ponds and cages satisfyingthe standards of will be purchased.

- Living fish are transported to the fishport of the factory by well-boats. Then,they will be put in the plastic tank andmoved to the raw material receiving area

7

by trucks. Here, QC staff will eliminatefish that do not meet the requirementsstipulated in the sales contract. Afterthat, fish are weighed and conveyed to thefactory. Afterwards, workers bleed fishand soak them in the water tank inpreparation for the implementation of thefilleting.

Bleeding,cleaning1,filleting

- Cleaning ≤4000 kg, thenwater exchange

- After being slaughtered, fishes are put inthe fresh water tank for soaking at thenormal temperature, time for soakingapproximately 15-20 minutes depending on thefreshness of the fishes. Every time ofcleaning does not exceed 4000 kilos offishes, then exchanging water. - Following cleaning, fishes are transportedto the filleting table by conveyor belt.Workers use specialized knives to cut meatpart at both sides of the fish, get rid ofheads, bones, intestines. During filleting,fish pieces are washed under sprayingfaucets with the aim of preliminaryelimination of blood on the fillets. Afterthat, semi-finished products are deliveredto cleaning 2- skinning off.

Cleaning 2,Skinning

off

- Cleaning atthetemperature ≤220C

- After filleted, fishes are weighed andwashed through the stuffing machines. Everytime of stuffing does not exceed 2000 kilos,then, water exchange. Fillet pieces arecleaned in order to take out its blood andslim. Semi-finished products are moved toskinning-off.- Workers use sharp knives to skin off pieceby piece by manual operations or bymachines. Yet, any touch on the belly andmeat part are not be made (skin is allowedto be left not over 10 % the fillet piecesurface). All operations must be quicklydone so as to shorten the time and not tostock products.

8

Trimming - T0BTP ≤ 100C - Fishes are weighed in each basket of 2,5kilos or 5,0 kilos, then, they are conveyedto every position of workers for trimming. - Workers use knives to cut fat, red meat,skin, artery, and bones left on the fillet.Next, semi-finished products will be removedto parasite checking.

Parasitechecking

- Skillful workers check each pieces offillet in accordance with technicalstandards. Any fillets do not qualified forthe requirements will be turned back and anyinfected with parasite will be eliminated.All operations must be quickly done so asnot to stock the products. - Semi-finished products after being trimmedwill be passed to the transparency table forparasite checking. Any parasite found on theproducts will be immediately got rid of theproduction line. QC staff will check thembefore addictive treatment.

Sizing,Cleaning 3

- T0 cleaning water ≤100C

- Cleaning 1500kilos, then exchanging water

- Fillets are sized as: 60-120, 120-170,170-220, 220-UP gr/piece, or 3-5,5-7,7-9…Oz/piece, under customers’ requirements.- Fishes are carefully washed in a veryclean water tank after sizing (via cleaningmachine system) at the temperature ≤ 100C,approximately 1500 kg, water exchange. Then,dry them in preparation for the addictivetreatment.

Addictivetreating

- 250 kg/piece- Solution temperature ≤10 OC

- Time: 10 – 15minute/ piece

- After cleaning 3, fishes will be treatedwith addictives. Medicine solution are readymixed in the proportion of 2.5:1(2.5 fish :1 solution) 250 kg for each, timefor treatment is 10 – 15 minutes in terms offish species and customers’ requirements)

Coloring,sizing

White, lightpink, darkpink, lightyellow, darkyellow

T0BTP ≤ 100C

- Fillets are colored as: W, LP, P, LY, Y…under customers’ requirements. Coloring mustbe quickly and exactly done in order tostock products.

9

Weighing 2,cleaning 4

- T0 cleaning water ≤ 80C

- Cleaning approximately200 kilos, then exchanging water

- Products are weighed in two forms:+ Block: Net weight per basket 4,5 or 5,0kg (under customers’ requirements)

+ IQF: Net weight from 0,9 to 1 kg(under customers’ requirements)- Each basket will be put a card with size,date of manufacture and specification inline with products. Operations must beaccurately and quickly done. - After weighed, products are carefullywashed through three clean water tanks atthe temperature ≤ 80. While washing, workersuse hands to cut the pieces softly to makeit cleaner. Every time of cleaning does notexceed 5kilo/ basket, not over 200 kgexchange water.

Tray-laying

- Drying products before tray-laying + Semi-finished products are arrangedin two forms: block and IQF + Fishes are individually arranged.Size card must be presentably put. Alloperations must be quickly done so as toshorten time and not to stock products.* Note: As for IQF freezing, if frozen byconveyor freezer, tray-laying does notexist.

Coldstorage

- Time for cold storage≤ 4 hours

- T0= -1÷ 40C.- Insulated

temperature-1 ÷ 40C

- Time for cold storage is not over 4 hours.Temperature in the cold store -1÷ 40C forblock), and in the cold storage tank -1 ÷40C for IQF semi-finished products.

Freezing - Freezing time for contact freezer ≤ 2.5 hours

- T0 ttsp ≤ -180C

- Semi-finished products are firstprocessed, first frozen.

For contact freezer, engine must be starteduntil a thin layer of snow covers on theplates. Then, freeze the products. Time forfreezing is not over 2.5 hours. For theconveyor freezer, engine must be starteduntil the temperature reaches ≤-400C. At thetime, freeze the products; time forfreezing is also up the size . Temperaturein the center of the products must reach ≤ -

10

180C

Tray off,glazing-

refreezing

- T0 glazingwater ≤ 50C

- For block, semi-finished products aretray-off its whole.

- For IQF, tray-off does not exist Use glazing devices to spray the products,temperature of glazing water colds down T0≤50C.

PE/PAwrapping,mental

detecting/packing

- For block: put each fish block in 1 PEbag, then, it will be metal detected andpacked in a carton. - For IQF: After frozen,glaze/refreeze/weigh and put in the PE/PAbag and seal carefully and metal detectedbefore packing in the carton. Time forpacking is not over 30 minutes. * Note: any packing designs are done inaccordance with customers’ requirements

Preserving T0≤ -200C - Preserving at the temperature T0≤ -200C- Temperature at the cold store recorded on

automatic thermometer




Doc code: HACCP I

Date of issue:

30/09/2011

Period of issue: 02

Amendment: 01

TABLE OF RISK ANALYSIS- Product name: Tra fish – Frozen Basa fillet- Preservation and distribution: preserving at≤ -200C and

distributing at ≤ -200C- Way of use: well-cooked before eating - Subjects: for all people

composition/

processing stage

Latent risks recognizedor controlled

Theimpact ofrisks onsafety

(Yes/No)

Comment, analysis, evaluation in column 3

Feasiblemeasures

Controlpoint(Yes/No)

(1) (2) (3) (4) (5) (6)

11

Receiving rawmateria

ls

Receiving rawmateria

ls

Biology:- Micro-

organism appear on theraw materials

- Infection of micro-organism

- Evolution of micro-oragnism

- Parasite

N

Y

N

Y

- Living fisheshave highresistanceagainst micro-organism and areoften well-cookedbefore eating

- Controlled bySSOP.

- Living fishesbear strongresistance

- Materials havethe possibilitiesof being infectedwith parasiteduring thefarming process

- Toeliminatethis risk,parasiteis checkedon thetransparency table

N

Chemistry:Prohibited antibiotic residues : The EU market: MG, LMG CAP, AOZ The US and NorthUS : MG, LMG CAP, AOZ Enrofloxacine,Ciprofloxacine,Flumequine

- limited antibiotics (Fluoroquinolones, Sulfonamides, Tetracyclines,Florfenicol, Trimethoprim)

Y

Y

- Due to farmersuse antibioticsto treat fishes’illnesses

Antibiotics areused to prevent andtreat fishes’illnesses

- Only rawmaterialslots whichhave agoodanalyticresult onprohibitedantibiotics will bebought

- Only rawmaterialsfromfarmingareas whichare undercontrol ofcompetentorgans will

Y

Y

12

- Aflatoxine toxin

- Other pesticide residues like: DDT, Hexachlorobenzen, Endrin, chlordan.. and heavy metals: Pb, Hg, Cd

Y

Y

- Fishes are ableto be infected withtoxin due to grainsare musty duringthe farming

- Fishes arecapable of beinginfected andretained pesticidesfrom paddy fieldsand from heavymetals available inthe environment

be bought Commitments andoriginpaper offarmersindicatethatantibioticsstop beingused beforeharvest

- Only rawmaterialsfromfarmingareas whichare undercontrol ofcompetentorgans willbeharvested- Commitmentand originpaper offarmersindicatethat mustyfeed willnever beused

- Only rawmaterialsfromfarmingareas whichare undercontrol ofcompetentorgans will

Y

Y

13

beharvested -Commitmentand originpaper

Physics: No

Killing andbleeding,

cleaning 1,filleting

Biology:- Infection of micro-organism

- Evolution of micro-organism

N

N

- Under control by SSOP and GMP

- Under control by GMP

Chemistry: NoPhysics: No

Cleaning2,

Skinning off

Biology:- Infection of

micro-organism


N

N

- Under control by SSOP.


Chemistry NoPhysics: No

Trimming


micro-organism


N

N

- Under control by SSOP


Chemistry: No

Physics: No

Parasite

checki


micro-organism

N - Under control bySSOP

14

ng - Evolution of micro-organism

- Parasite

N

Y- Under control by

GMP

- Parasite may beleft duringchecking

- QC staffrecheck semi-finished products

Y

Chemistry: No

Physics: No

Cleaning 3

Biology:- Infection

of micro-organism


N

N




Addictive

treating

Biology:- Infection

of micro-organism


N

N



Chemistry: -P2O5 residues -Prohibited antibiotics: CAP, AOZ

N

N


- Under control by GMP.

Physics: No

Coloring andsizing

Biology:- Infection

of micro-organism


N

N



15

Chemistry: No

Physics: No

Weighing 2,

Cleaning 4

Biology:- Infection

of micro-organism


N

N




Traylaying

Biology:- Infection

of micro-organism


N

N




Coldstorag

e

Biology:- Infection

of micro-organism


N

N




freezing

Biology:- Infection

of micro-organism

N - Under control by SSOP


Trayoff,

glazin


micro-N - Under control by

SSOP

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g organism


PE/PAwrapping Mentaldetecting

Biology:- Infection

of micro-organism

N - Under control bySSOP

Chemistry: N - Under control bySSOP

Physics: Y - Metal pieces maybe mixed in the products during production

- Metal detector will spot and eliminate (ÞFe ≥1.5, Þ SUS ≥2.0 available in the products)

Y

Packing

Biology: N Under control by SSOP


Preserving

Biology: NoChemistry: NoPhysics: No

Dated September 30, 2011 Approved by

17




Doc code: HACCP I

Date of issue:

30/09/2011

Period of issue: 02

Amendment: 01

GENERAL TABLE OF CCP

NoStages/

compositions

Risks CH1(Y/N)

CH2(Y/N)

CH3(Y/N)

CH4(Y/N) CCP

1.Receiving raw materials

BIOLOGY- Parasite Y N Y Y N

CHEMISTRY- Prohibited

antibioticresidues

- Permissibleantibioticresidues

- Aflatoxin toxin- Pesticide

residues, heavymental

YY

Y

Y

NN

N

N

YY

Y

Y

NN

N

N

YY

Y

Y

2. Parasite checking

BIOLOGY- Parasite Y Y Y

3. Metal detecting

- Metal pieces Y Y Y

Dated September 30, 2011 Approved by

18

INTERNATIONAL DEVELOPMENT AND INVESTMENT CORPORATION IDI FRESH FISH FACTORY No1 WORKSHOP I Factory...

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