Haccp Manual Mgh-Epz LTD - 2019

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MERU GREENS HORTICULTURE EPZ LIMITED - HACCP MANUAL- HM 01

MERU GREENS HORTICULTURE EPZ LIMITED


HACCP MANUAL(HM):
Ref No. HM 01
PROCESSED BEANS IN PODS IN GLASS JARS AND CANS

Issue/Revision: 06/05
Issued Date: FEB 2019
Super cedes: Issue 05

Prepared By: _____________________


Approved By:_____________________

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MERU GREENS HORTICULTURE EPZ LIMITED - HACCP MANUAL- HM 01

Document : HACCP Manual: Ref. No : HM - 01


Processed Beans in pods Packed in Jars Date: February 2018
and cans

Title: Table of content Page No: 1


Prepared By: Approved By:

1.0 Table of Content


2.0 Distribution Record sheet
3.0 Amendment record sheet
4.0 General
5.0 HACCP team
6.0 Scope
7.0 Terms of Reference
8.0 Product and Process Description
9.0 Intended Use
10.0 Verification
11.0 Flow Chart
12.0 Hazard Analysis
13.0 PRP plan
14.0 oPRP plan
15. 0 HACCP plan.
16.0 Decision tree

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MERU GREENS HORTICULTURE EPZ LIMITED - HACCP MANUAL- HM 01

2.0 Distribution Record Sheets

Document being held at the Q&FSM office


3.0 Amendment Record Sheet
Ref. No Revision No. Details Reviewed Revision Prepared By Approved By
Date
   1  Included more beans varieties and  25.08.2016  Food Safety Operations Manager 
defined further potential misuse of Team Leader
the product
   02  Included more references. Included 04.02.2017   Food safety  Operations Manager 
cans in the scope. Changed Team Leader
approving Authority from Factory
Manager to Operations Manager
   3  Changed the QAM office to  9/2/2018  Food safety  Operation Manager
Q&FSM. Team Leader
Changed French beans to Beans in
pods.
Changed the number of team
members from 4-8 to 4-12.
Added citric acid in the product
composition.
Added addition of citric acid in the
processing details.
Included caps in the packaging
details.
Added the process flow diagram 4.
Changed CCP 1 on flow diagrams
1&2 to CCP2.
Changed the position of cutting the
raffia grass into size in the flow
diagram 2.
Changed the cold room storage
temperature from 8±2º C to 4-10ºC

4 Changed the target temperature 22.11.2018 Food safety Operations manager


(critical limit) of 72cl jars to Team Leader
13minutes from 14.5minutes.
5 In the list of team members, 21.02.2019 Food safety Operations manager

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MERU GREENS HORTICULTURE EPZ LIMITED - HACCP MANUAL- HM 01

replaced Joyce Makena with Team Leader


Florence Ariko and Stephen Kyalo
with Dominic Muchangi

GENERAL
Management commitments to food safety, quality and customers’ satisfaction is demonstrated in the
adoption of HACCP model to enable the company to meet its food safety, quality and business objectives.
This manual has been developed based on CODEX HACCP Principles 1997 and other applicable regulatory
and statutory requirements and industry codes of practice.

It’s intended to provide food safety and quality framework for production of processed beans in pods
(commonly known as French beans) in jars and cans by Meru Greens Horticulture EPZ ltd. The manual is
subject to review from time to time as may be deemed necessary with regards to new developments in the
industry or significant changes within the production processes that may affect quality & safety of the
product such as;

 changes in raw materials or supplier of raw materials where applicable


 changes in ingredients/recipe
 changes in processing conditions or equipment
 changes in packaging, storage or distribution conditions
 changes in consumer use
 emergence of new risk, for example adulteration of an ingredient
 development of Scientific information associated with ingredients, process or product

This manual must be reviewed annually as a bare minimum to ensure effectiveness in managing product
quality & safety as well as in pursuit of meeting the company business objectives. The major review shall
be taken in the month of April of every year

During its development, reference has been made to the following:


 Code of Hygiene Practices for Low and acidified low acid canned Foods (CAC/RCP 23-1979)
 Canadian Inspection Agency: Chapter 4: can examination and evaluation procedures
 FAO Corporate Document Repository. Canning/Sterilization of meat products. (Principles of
Food Canning).
 Food Sterilization by heat. A Casolari

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MERU GREENS HORTICULTURE EPZ LIMITED - HACCP MANUAL- HM 01

 HACCP: Identification of CCP, CP, PRP, oPRP in the standards of IFS, BRC, ISO 22000-
Practical examples by Dr. Bernhard Mueller, Auditor & Owner of SAFEFOOD-ONLINE, 29-
01-2014
 Codex standard for canned Green beans and Canned wax beans. Codex Stan 16-1981
 Laws of Kenya. Public Health Act Chapter 242
 Food Drugs and Chemical substances CAP 254, Revised Edition 2012
 Codex Alimentarius. Food hygiene. Basic Text, Fourth Edition
 Kenya Standards, KS CAC/RCP 2:1969 ICS 67 020 on Recommended International Code of
hygiene practice for canned fruits and vegetables products
 Kenya Standard KS EAS 39:2000 ICS 67:020 on hygiene in the Food and drink manufacturing
industry-code of practice, confirmed 2014
 HACCP; A practical Guide 4th Edition by Campden BRI

5. HACCP TEAM

The team created shall comprise of 4-12 members who possess the necessary skills and have knowledge
about the associated hazards. This team shall be multidisciplinary deriving members from each of the
following functions

a) Operations (Production, Engineering and Quality)


b) Raw material
c) Finance (Mainly procurement)

6. SCOPE
The HACCP manual covers production of Processed Beans in pods in Glass Jars and cans produced by Meru
Greens Horticulture EPZ ltd from green/yellow beans in pods right from receiving point of the raw
materials, packaging materials, storage, and production to dispatch of the finished product to the
customers.

7. TERMS OF REFERENCE
Shall consider, all elements of food safety i.e.
 Biological
o Microbiological spoilage: Survival and multiplication of spoilage and pathogenic micro-
organisms
 Chemical
o Chemical contaminants such as pesticide residues, heavy metals, cleaning detergent
residues, disinfectants, lubricants etc.
 Physical
o Foreign bodies such as plastic, glass, insects etc.

 Prerequisite programs to assist in the control of food safety hazards to the product through the
work environment, cross contamination between product and controlling food safety hazards
levels in the product and product processing environment
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MERU GREENS HORTICULTURE EPZ LIMITED - HACCP MANUAL- HM 01

 Food Allergens: list as per Regulation (EU) No. 1169/2011 of the European Parliament and of the
Council of 25 Oct 2011, Annex II on substances or products causing allergen or Intolerance.

8.0 PRODUCT AND PROCESS DESCRPTION


a) Composition
The canned product comprises: -
1. Green or yellow beans in pods (Phaseolus vulgaris)

2. Edible Salt – non-iodized salt

3. Water – potable water

4. Citric acid

b) Origin of ingredients

French Beans Harvest areas


The beans in pods are grown in different regions commonly known as counties within Kenya. The company
has penetrated most counties which include and are not limited to;
Rift Valley, Meru, Kiambu, Murang'a, Embu, Kirinyaga, Makueni, Machakos, Tharaka Nithi among other counties.

Water - supplied by the City Council of Nairobi through the Export Processing Authority (EPZA).

Non-iodized Edible salt - supplied by Kensalt Ltd

Citric acid – From approved suppliers (see procedure PM -6-20)

c) Physical and chemical properties

Bean in pod is a narrow pod normally harvested before development of seeds. It is defined as an immature
and fragile vegetable. It is a highly perishable vegetable with a high moisture content (high aw) that requires
fast picking, transportation and processing before losing its freshness. It is a low acid vegetable and
therefore the deteriorating micro-organism after harvesting is mainly mould. It is a low acid vegetable with
a pH of more than 4.6.
It has a tendency of reacting to adverse weather conditions forming a ligneous tissue in the main supply
vein. This is a very resistant tissue known as a string which is undesirable to consumer.
It exists in different sizes/ diameters which are as classified below:-
Diameter Quality
0.0 - 4.0mm Super Extra Fine (SEF)
5.0 – 6.5mm Extra Fine (EF)
6.5 – 8.0mm Tri-Fines (TF)
> 8.0mm Overgrown/ Oversize
d) Processing details:-

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MERU GREENS HORTICULTURE EPZ LIMITED - HACCP MANUAL- HM 01

Key process steps include, raw material inspection aimed at assessing the quality and safety of the product
at receiving, snipping (removing the fibrous ends), washing, blanching, packing into jars/cans, hot filling
using brine solution (mixture of edible salt and potable water) or addition of citric acid (when yellow beans
are involved), hermetic sealing (seaming for cans and capping for jars) and sterilization. The sterilization
process is so designed in relation to temperature/ time combination aimed at destroying the most heat
resistant spore forming anaerobic bacteria called Clostridium botulinum. Elimination of this microorganism
is seen as the minimum heat treatment needed to completely eradicate pathogenic microorganisms.

e) Packaging information

This involves both primary and secondary packaging.


Primary packaging involves filling the blanched beans in either cans or jars of different sizes capped with
caps with a safety button
Secondary packaging is employed after sterilization. This involves packing the labelled cans/jars into trays
and shrink-wrapping with polythene film or packing the labelled cans and jars into cartons.

f) Storage conditions, transportation and shipment

To be stored in a cool, dry place at temperatures preferably 10 -20 OC but can extend up to 25°C.
Temperatures above this could cause accelerated aging and subsequently reducing the shelf life.
The finished product is transported by road in sealed containers to the port where they are then loaded to the
ship for final transportation by sea. Other options which could apply is the use of rail transport which is
under consideration by the management.

g) Shelf life
The process is designed as to keep the product safe for a period of 4 years for jars and 3 years for cans. The
shelf life will be influenced by the quality of lacquer for cans and caps, while stored at ambient
temperatures stated above. The product is coded as a “Best Before”. The transportation method shall be
such that the product is maintained intact with minimum vibration to avoid possible loss of vacuum which
could subsequently lower the shelf life.

h) Labelling instructions

Product processed at Meru Greens Horticulture is labelled using private labels where Meru Greens has very
little influence on it. The label design and labelling is customer focused in the sense that the customer
designs the label with relevant details. Such details include the weights which are Net Drained Weight, Total
Net Weight and the container capacity. It also details the nutritional values of the product, ingredients and
instructions for use.

i) Intended use/Intended consumer/ target group

Canned beans in pods are ready to eat vegetable product with no known allergenic concerns. The product is suitable
for consumption by all age groups. The product acquires a tolerable degree of softness during processing hence can be
served to infants, elderly and sick persons with minimal assistance from caretakers.

j) Potential for misuse

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MERU GREENS HORTICULTURE EPZ LIMITED - HACCP MANUAL- HM 01

Mis-handling during transport and storage especially glass jars which could result in loss of vacuum in case
of knocks on the cap.

Storage at temperatures less than 0 OC and any possible quick and high temperature deviations during
storage.

Failure to follow instructions on the label regarding storage after opening

10. VERIFICATION
The HACCP manual implementation shall be verified through:
 Daily review of records - this includes records where CCPs are monitored.
 Review of customer complaints or complaints from regulatory authority concerns.
 Trainings of workers
 Mandatory annual review & validation
 Audits: Customer, 3rd party or Internal audits

11.0 VALIDATION AND REVALIDATION OF THE CCPs

MGH Shall have an initial validation and a routine revalidation of the CCPs on a defined frequency. The re-
validation shall be done once a year between the months of July and September of each year.

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