Good Manufacturing Practices (GMP)

superb Manufacturing Pract applesauces (GMP)3.1. IntroductionGMP the building blocks for HACCP. In several old age, producer, retailer and industrialist use up correct Manufacturing Practices (GMP) as suppress method acting in order to produce corking part of fodder. whole just about producers control on developing GMP regulations. Now, it uses as demand program on HACCP system or provender asylum system. obedient Manufacturing Practices should be selected and adopted before HACCP is implemented. Without the application of CGMP principles, an effective HACCP program crapper non be conducted. Furthermore, GMP mustiness be applied to the development of sanitation standard run procedures (SSOP). Compliance with specific GMP should be holdd as slice of HACCP. The argonas that should be addressed by CGMPs atomic number 18 personal hygiene and new(prenominal) practices, buildings and facilities, equipment and utensils, and doing and process get the hangs. CGMPs sh ould be broad in nature (Marriot, two hund rose-cheeked7). in that location can hardly be HACCP without pricey Manufacturing or Management Practices (GMP). Briefly, GMP is a description of either the steps (which should represent goodness practice) in a bear upon facility, while HACCP is a documentation that the steps important to consumer health be under control (Arvanitoyannis and Theodoros, 2009)GMP application is excessively a basic break dance of Total Quality Management Program (TQMP). GMP application should be explain in briefly and clearly round problems and procedures on e precise confront on victuals for thought touch.3.2. DefinitionGMP and SSOP atomic number 18 interrelated and an important part of process control. CGMP atomic number 18 the marginal sanitary and processing c both in all forments necessary to check the turnout of wholesome meat. GMP is one of supporting program for implementation of HACCP system. GMP conciliate food for thought prod uct contrive a good timberland and guard it is in addition make product widely acceptable for consumers in interior(prenominal) and international market.Based on Ministry of Marine Aff line of c fierceit and Fisheries Regulation (2007), GMP is the guide telephone circuit on good prerequisite and production procedures on tilt processing unit.GMP is a combination of the production and quality control, to ensure that food manufacturers or processing be following the right step of its production line consistenly and spesifically. GMP refers to the regulation that firstly decl atomic number 18d by the US Food dose Administration (FDA) after being revised in 1986.GMP regulation is aimed to foster the consumer to avoid purchasing any dangerous or contaminated products. Its require a good quality approach of manufacturing and processing product to come about errors and failure. Nowadays, the consort of GMP is getting more important as pre-requisite program of HACCP on that p ointof it has to be implemented prior the HACCP system together with the application of SSOP.3.3. mount fit to Darwanto and Murniyati (2003), on operational processing unit, company management should be check on processing activities for evaluatinga. suitability, quality, and all input factor much(prenominal)(prenominal) as look for, food additives, ingredients, packaging, labeling etcb. control suitability and condition of manufacturing viz. construction, maintenance, sanitation, operation, and equipments that ar use on seek processingc. fulfillment of end products requirements are quality, safety, healthy, and as sanitary as composition and grade of quality on productd. round checking on their health, hygiene and qualification.3.4. GMP components3.4.1. Location and Building Requirement3.4.1.1. LocationSeafood congeal is consider of a suitable location. Some factors should be considered namely physical, geographic and infrastructure ready(prenominal). A plant must be ade quate on a plot of adequate size, easy access on battery- red-hot by road, rail or pee. An adequate of water should be available throughout the year. Seafood plants contain significant amounts of organic matter which must be removed before waste water is discharge into river or the sea. It as well solid waste handling needs careful or appropriate planning, appropriate space, must be available. The immediate physical surroundings of a seafood pulverisation should be landscape and present on attractive compute to the visitor. Shrubbery should be at least 10 meter away from mill building and a grass free strip covered with a layer of gravel should follow the outer wall of buildings (Huss, 1994).In addition, the manufactory location should be large enough for expansion and should be attractively landscaped with natural features such(prenominal) as tree persist ined wheresoever possible. Paved or asphalt area are needed in factory, car pack should be situated at a presumable wa lking blank space from the factories to reduce fumes and noise (Forsythe and Hayes, 1998).3.4.1.2. Building in that respect are several requirements for angle factories buildings. The materials that utilise on building materials should be have the specific characteristics. there are specific characteristics such as non-porous, non-toxic, easily lighted, rodent proof, tranquil flat, etc.According to Huss (1994), on food processing industries should have the particular characteristics on materials which are use on food industries. Food factories should be designed and built for particular purposes with materials open(a) of withstanding various physical conditions. The principal factors to consider are horniness, cold, humidity, and vibration.On tilt processing, interior step forwards should be beam, non-porous, easily cleaned and not vulnerable to chemical substance bombardment by modern detergents and disinfectants, or able to sustain biological/microbiological growth.Goo d natural light and screened electric light must be provided. Paints and new(prenominal) surface coats should be non-toxic and not flake those that contain mould inhibitors must not come into amour with foods.Pipe performance, drainage ducts, conduits for power furnish and other channels should be tightly sealed where they pass through walls, floors and ceilings to encumber entry of vermin and insects (Huss, 1994). bash pipe work sometimes passes directly over process lines and water condensed on the pipes can trickle on the underlying food and equipment (Forsythe and Hayes, 1998).Ventilation on seek factory have to efficient and ceiling should be constructed of and finished with materials that obviate condensation, create flatting, and mould growth. The panel construction being made of various PVC, reinforced resins, PVC-faced plasterboard, PVC-foil-faced foam board or plastic-coated steels (Forsythe and Hayes, 1998).Walls should be constructed with durable materials and in trustworthy situation. All wall angles, corners and junctions of walls and floors must be imperiously sealed and be rounded for ease of change. Coving of the wall/floor junction of walls to a vertex of. C. 15 cm. Modern materials that are apply on wall intromit polypropylene and different PVCs. capable polymers and glass-reinforced PVC can be mould on a thin metallic surface with a cladding of suitable insulating materials (Forsythe and Hayes, 1998).Floor is that surface should be non-slip and easy to clean and disinfect. The quality of the floor surface can be improved by exceed the cover with appropriate materials. These include epoxy, polyester or acrylic resins, chlorinated and styrene butadiene rubbers and bituminous paints and mastics. The resins have a number of advantages such as durable, easy to clean, good non-slip surface, change surface but became saturated and absorb water under water condition. Tiles can provide a relatively long lasting and mothproof su rface. However, there are weaknesses since they crack, lift to be under run by water, and are difficult to replace satisfactory (Forsythe and Hayes, 1998).Ideally, building have to call no constraints on any process or plant layout. However, production line are sited in unsuitable buildings as an economic necessity. bend of building can be base on reinforce concrete or steel frame. In the framed structure the orthogonal walls are essentially a skin design to protect personnel and equipment inside. It mover that the external walls can be constructed of relatively light material namely aluminum (Forsythe and Hayes, 1998).3.4.1.3. Plant layoutLayout of food industries be laid out with clear, rather straight through lines of product ascend. Final or intermediate processes must be separate to avoid cross- contamination by crank materials.According to Kotschevar and Terrell (1977) in Forsythe and Hayes, (1998), there are eight principle in efficiency flow of work in food service a rea arefunction should proceed in proper sequence directly, with a minimum of criss-crossing and backtrackingsmooth and rapid productiondelay and storage of materials in processing should be eliminated histrion and materials should cover minimum distancesmaterials and tools should receive minimum handling, and equipment minimum worker handlingmaximum utilization of space and equipment should be achievedquality control must be sought at all critical pointsminimum cost production should be sought.With eight principles, these layouts go away minimize recontamination of angle process or raw materials.The preparation areas for all raw materials and all product should be physically separated by appropriate walls. The consummation of operators surrounded by the separate processing areas should be use of allocated colored costume and control by management.Facilities for washing hands with knee or innovation operated hot water taps should be positioned at all prosaic entrances in foo d factories as well as in the toilets. Suitable liquid unperfumed soaps, barrier creams and disposable towels must be provided at all times, with instruction given also their proper use.Floors should be durable, smooth, easily cleaned and cautiously insulated in addition, because of the problem of frost heave where the subsoil becomes frozen to a depth of 1-2 cm causing weakening of the foundations, a heating walls and ceiling should also be durable, smooth and easily cleaned material such as galvanized steel is particularly recommended.Design layout of cold stores should aim at safekeeping the environment as constant a possible. Thus the entry of unassailable air should be minimized by providing properly insulated double doors with an air lock and, as with chill rooms, sitting should be some distance form warm processing areas.3.3. The examples of processing layout A = administration, EA = employee amenities, FPS = final products storage, L = laboratory, P = production area, RMS = raw materials storage (Forsythe and Hayes, 1998 re-draw by the authors)3.4.1.4. EquipmentsThere are seven basic principles for hygienic design agreed by the operative Party appointed by the Joint Technical Committee of the Food Manufacturers Federation (FMF) and the Food Machinery Association (FMA) in Forshyte and Hayes, (1998). The principle areall surface in contact with food must be unemployed to the food under the condition of use and must not transmigrateall surfaces in contact with food must be smooth and non-porous so that tiny particles are not caught in microscopic surface crevices and become difficult to dislodgeall surfaces in contact with food must be visible for inspectionall surfaces in contact with food must be readily accessible for manual cleaningall surfaces in contact with food must be put that the equipment is self-emptying or self-drainingequipment must be design as to protect from external contaminationthe exterior or non-product contact surfaces should be arranged to stay fresh harboring of soils, bacteria, or pest in and on the equipment itself as well as in its contact with other equipment, floors, walls or hanging support.With the above principle, materials are commonly utilise in food processing are chromium steel steel, iron and mild steel, copper and its alloys, miscellaneous metal, plastics, rubber, glass and wood, and antimicrobial work surfaces (Forsythe and Hayes, 1998).Manufacturing equipment should be designed to prevent the entry of foreign materials, and the development of out-of-sight drained spots, specially within the operation chamber and associated pipe work. Bolts and clips should be abandoned externally to maintain all internal product contact surfaces smooth and easily cleaned. For operator safety, all equipment should be made safe by electrical isolation during dismantling and cleaning.Table 3.1. Applications of materials-handling equipmentsConveyorsElevatorsCranes and hoistsTrucksPneumatic equipments w ater flumes way of lifeVertical up***Vertical down*** run away up***Incline down****Horizontal*** FrequencyContinuous****Intermittent** Location served heading****Path***Limited areaUnlimited area** HeightOverhead****Working height****Floor level****Underfloor***MaterialsPacked****Bulk****** steady******Liquid** ServicePermanent*****Temporary**From Brenan et al (1976) in Fellow, P.J. (1990)3.4.2. working(a) Requirements3.4.2.1. Receiving Raw MaterialReceiving raw materials should be consider some requirements such as the origin of raw materials, species and size based on product, quality of raw material and end-product.a. Indicators of Fish FreshnessOn the receiving materials area, sensory analysis is the main method of evaluating fish crust. It enables differences in texture, shade, and taste to be determined, and later the reusableness of the raw material. Sensory properties change during storage from the desired very high standard, through neutral or average, and finally t o undesirable or disgusting. It is generally assumed that prior to disappearance of desirable features the fish is considered to be fresh, while the appearance of undesirable or disgusting features disqualifies the raw material. The approximately difficult step is to determine an intermediate state in which the fish is not entirely fresh. Sensory analysis is thus carried out on raw fish and cooked fish. Flavor, appearance and state of abdominal cavity (for not eviscerated fish) are the main indicators of quality in the case of raw fish. For cooked fish, sniff out is the around important indicator (Hall, 1997).In addition, microbiological test on raw material is important parameter. In raw materials not only use sensory test but also use microbiological test. Particularly, on freshness test of tuna for sashimi, commonly use K value methods. K value is one of chemical methods based on ATP degradation. This method is commonly use on Japan to measure fish freshness.According to Anony mous (2002), checking the following at receipt go out confirm seafood safety and freshnessproduct temperature (chilled seafood should be below 5oC but ideally between -1.5o and 2oC frozen seafood should be below -18oC),package condition and use-by-date of pre-packaged seafood,hygiene and cleanliness of the transferee vehicle,a record of the species, harvest date and location, and suppliers name, andvisual quality criteria. thus far if quickly frozen after catch, frozen seafood will not keep indefinitely. Bacterial activity ceases below about -10oC, but chemical and biochemical changes (enzymes, oil oxidisation, and dehydration) will still occur. These changes may bring about disinclined irreversible changes in odor, odor, and appearance. For long term freezer storage, it is recommended that a temperature of -30oC is maintained (this may only be achieved by commercial freezers). Seafood stored at -15oC (domestic freezers) will have a much-reduced shelf life.3.4.2.2. Handling a nd ProcessingFish and shellfish are considered to be among the most perishable foodstuff. To keep fish cool, backpacking in ice is use this methods is avoids the possibility of the temperature dropping to low with the auxiliary freezing of the flesh of the fish. During fish handling and processing in fisheries processing, it will retard the fish deterioration. Keeping fish I the cool thus extends the high-quality life (HQL) of the fish. Good chilling practices on board the fishing vessels and on shore result in better quality fish which, on landing (Garthwaite, 1997).Chilling delays and minimizes spoiling and the ideal chilling system cools fish rapidly to wet ice temperatures. It is essential to minimize bacterial contamination of the fish during all stages of handling. Dirt should be washed off the fish as landed and the surfaces with which the fish come in contact be maintained in a clean condition. Care must also be taken to wash the fish after gutting it, and to use clean i ce. Fish properly iced will cool rapidly and will retain quality for 1 to 2 weeks, depending on the species. Ease handling, reduction of exercising weight loses, and elimination of bruising are advantages to be considered in short-term storage in refrigerated seawater (Shapton and Shapton, 1991).Since peewit live only a few minutes after removal from their natural habitat, microbial spoilage starts immediately through marine bacteria on the surface and in the digestive system, and through microorganisms which happen to contaminate the prawn on the ships deck, in handling, and from iced used during their storage. The taproom of deterioration in the quality of fresh and iced-stored shrimp involves not only maintaining low microbial count but also prevention of oxidation (Shapton and Shapton, 1991).Temperature and time conditions at all steps from catching or harvesting to distribution is important to prevent growth of infective bacteria, histamine producing bacteria and spoilage b acteria. Temperature and time also are important in preventing oxidation and chemical spoilage (Huss, 1994).3.4.2.3. Additives and chemical materialsAdditives and chemical material commonly use on fish processing. It usually used on fish value added product.1. AdditivesAdditives can be divided into six major categories protectives, nutritional additives, flavoring agents, people of color agents, texturizing agents, and miscellaneous additives (Branen and Bragerty, 2002).a. PreservativesThere are basically triplet types of preservatives used in foods antimicrobials, antioxidants, and anti-browning agents. The antimicrobials are used to check or prevent the growth of microorganisms. The antioxidants are used to prevent lipid and/or vitamin oxidation in food products. They vary from natural substances such as vitamins C and E to synthetic chemicals such as butylated hydroxyanisole (BHA) and butylated hydroxytoluene (BHT). The antioxidants are especially useful in preserving dry and frozen foods for an extended period (Branen and Bragerty, 2002).Anti-browning agents are chemicals used to prevent both enzymatic and non-enzymatic browning in food products, especially dried fruits or vegetables. Vitamin C (E300), citric harsh (E330), and sodium sulte (E221) are the most commonly used additives in this category (Branen and Bragerty, 2002).b. chemical substance preservativesThe action of maximum and minimum limit of chemical curing and preservative agents should be safe usage known (Betty and Diane, 1987).Propionic acid, sorbic acid, benzoic acid and shulphur dioxide are effective as a preservative. Propionic acid and its salts are mould inhibitors. Sorbic acid is useful fungistatic agent for use in flour confectionery, marzipan and cheese. benzoic acid occurs naturally in cranberries and is added to many other foods. It is more effective against moulds and yeast than bacteria. These compound are most effective at the worst pH values of food and ineffective at neu tral pH.In addition, sulphur dioxide is being effective in inhibiting microbial growth, also helps to maintain the color of vegetable that are going to be processed (Betty and Diane, 1987).Nitrates and nitrites are used as a curing for meats. Due to toxicological concerns there has been a tendency to reduce the concentrations used in new years. This imparts a red coloration to the meat similar to fresh meat (Betty and Diane, 1987).c. nutritionary AdditivesNutritional additives have change magnitude in use in recent years as consumers have become more concerned about and interested in nutrition. Vitamins, which as indicated above are also used in some cases as preservatives, are commonly added to cereals and cereal products to deposit nutrients lost in processing or to enhance the overall nutrient value of the food. The addition of vitamin D to milk and of B vitamins to bread has been associated with the prevention of major nutritional deficiencies. Vitamin A, from liver cod, is essential for normal vision, growth, cellular differentiation, reproduction, and oneness of the immune system (Branen and Bragerty, 2002).In addition, Carotenoid on food can be functioned as function not only as color and nutrient compounds but also as antioxidants (Branen and Bragerty, 2002). Carotenoid can help to minimize aerophilic damage and reduce the risk for age-related disorders by preventing the accumulation of free radicals (Rosalee and Michael, 2008). In addition carotenoid also found on brown algae (Miyashita and Masashi, 2008)Minerals such as iron and iodine have also been of extreme value in preventing nutritional deficiencies. Proteins or proteinaceous materials such as soja bean protein also are sometimes used as nutritional additives, although they are most commonly used as texturizing agents.Fiber additives have seen increased popularity in recent years with the increase in consumer interest in dietary fiber. Various cellulose, pectin, and starch derivatives h ave been used for this purpose.d. Coloring Agents more or less coloring agents are used to improve the overall attractiveness of the food. A number of natural and synthetic additives are used to color foods. In addition, sodium nitrite is used not only as an antimicrobial, but also to fix the color of meat by interaction with meat pigments (Branen and Bragerty, 2002).There are two kinds of coloring agents natural coloring and synthetic coloring. intrinsic coloring made from plants and animals (Table 3.4.). Synthetic coloring made from chemical substances (Table 3.5.).e. flavourer AgentsFlavoring agents comprise the greatest number of additives used in foods. There are three major types of flavoring additives sweeteners, natural and synthetic flavors, and flavor enhancers (Branen and Bragerty, 2002).Table 3.2. chemical preservatives and their dose that are leaded for using in food processing (Indonesian Ministry of wellness Regulation No. 722/Menkes/Per/IX/88)NoChemical Preservat ivesKinds of Food utmost dose1Sulphur dioxideMarmalade tomato feastSugar PowderPowder dextroseSugarVinegarsirupWineGrapeSausageDried coffee suggest gelatin c mg/kg350 mg/kg20 mg/kg70 mg/kg70 mg/kg70 mg/kg70 mg/kg200 mg/kg450 mg/kg150 mg/kg1 g/kg d mg/kg2 one thousand Bi sulphateFrench friesFrozen shrimp genus Ananas essence purify50 mg/kg10 mg/kg (raw) 30 mg/kg (cooked)50 mg/kg3Potassium MetabisulphateFrench friesFrozen shrimp50 mg/kg speed of light mg/kg4Potassium process totalCheese euchre mg/kg50 mg/kg5Potassium nitriteMeatCorned125 mg/kg50 mg/kg6Potassium sulphateFrench friesFrozen shrimp pineapple plant essence extract50 mg/kg100 mg/kgergocalciferol mg/kg7Natrium BisulphateFrench friesFrozen shrimpPineapple essence extract50 mg/kg100 mg/kg500 mg/kg8Na-metabisulphateFrench friesFrozen shrimp50 mg/kg100 mg/kg9Natrium nitrateMeatCheese500 mg/kg50 mg/kg10Natrium nitriteMeatCorned125 mg/kg50 mg/kg11Natrium sulphateFrench friesFrozen shrimpPineapple essence extract50 mg/kg100 mg /kg500 mg/kg(Cahyadi, 2006)The most commonly used sweeteners are sucrose, glucose, fructose, and lactose, with sucrose being the most popular. The most common additives used as sweeteners are low-calorie or non-caloric sweeteners such as saccharin and aspartame. In most cases, flavoring agents are the same chemical mixtures that would naturally provide the flavor (Branen and Bragerty, 2002).f. Texturizing AgentsThese agents are used to add to or modify the overall texture or mouth feel of food products. Phosphates and dough conditioners are other chemicals that play a major role in modifying food texture. Lecithin and mono- and diglycerides as well as several synthetic derivatives. The chief(a) role of these agents is to allow flavors and oils to be dispersed throughout a food product (Branen and Bragerty, 2002).Stabilizers include several natural gums such as carrageenan as well as natural and modified starches. These additives have been used for several years to provide the desir ed texture in products such as ice cream and are now also finding use in both dry and liquid products. Carrageenan found in red algae (Yuan, 2008).Phosphates are often used to modify the texture of foods containing protein or starch. These chemicals are especially useful in stabilizing various dairy and meat products. The phosphates apparently react with protein and/or starch and modify the water-holding readiness of these natural food components (Branen and Bragerty, 2002).Benefits of AdditivesThere are obviously many acknowledge benefits to be derived from additives. Some of the major benefits are a safer and more nutritious food supply, a greater choice of food products, and a lower-priced food supply (Branen and Bragerty, 2002).Risks of AdditivesThe indirect risks that have been described for additives are the converse of some of the benefits attributed to their use. Additives have also resulted in the increased availability of food products with a low density of nutrients.Of greater concern than the indirect risks are the strength direct toxicological effects of additives. Cancer and reproductive problems are of primary concern, although there is no direct evidence linking additive consumption with their occurrent in humans.2. Chemical SubstancesSome chemical substances use in fish/food processing. They used on processing area and products. These substance have used based on government regulation. If they not used based on it the product will be danger to consumers. Several chemical substances are used on fish processingTable 3.3. original preservatives and their dose that are allowed for using by Indonesian Government (Indonesian Ministry of Health Regulation No. 722/Menkes/Per/IX/88)NoOrganic PreservativesKinds of FoodMaximum dose1benzoic acidSoy sauce dim drinkCucumber pickle glycerol trimargaratePineapple essence extractOther foods600 mg/kg600 mg/kg1 g/kg1 g/kg1 g/kg1 g/kg2Propionic acidCheese profits3 g/kg2 g/kg3Sorbic acidCheese3 g/kg4Benzoic PotassiumMargarinePineapple essence extractDried ravisherJam and jellySyrup, tomato sauceGrapeOther food except meat, fish, fowl1 g/kg1 g/kg500 mg/kg1 g/kg1 g/kg200 mg/kg1 g/kg5Propionic potassiumCheese3 g/kg6Sorbic potassiumCheeseRaw cheeseMargarineDried apricotCucumber pickleJam and jellyMarmaladePineapple essence extract3 g/kg1 g/kg1 g/kg500 mg/kg1 g/kg1 g/kg500 mg/kg1 g/kg7Benzoate PotassiumPineapple essence extract1 g/kg8Methyl-p-hydroxyl benzoicCucumber pickleLiquid coffee extractTomato paste, essenceOther food except meat, fish, fowl250 mg/kg450 mg/kg1 g/kg1 g/kg9Natrium benzoateJam and jellySoy sauce dim drinkOther foods1 g/kg600 mg/kg600 mg/kg1 g/kg10Natrium propionic tone of voice at on propionic acid verbal expression at on propionic acid11NisinCheese12.5 mg/kg12Propil-p-hydroxyl benzoicLook metal-p-hydroxyl benzoicLook metal-p-hydroxyl benzoicSource Cahyadi, (2006)Table 3. 4. Natural coloring agents characteristicGroupColorSourcesSolubilityStabilityCaramel cookCooked su garWater lastingAnthosianineOrange, RedBluePlantsWater splendid to heat and pHFlavonoidWithout yellowPlantsWater fixed to heatLeucoanthocianine neutralPlantsWaterStable to heatTanninColorlessPlantsWaterStable to heatBatalineYellow, redPlantsWaterSensitive to heatQuinonYellow-blackLichenWaterStable to heatXanthonYellowPlantsWaterStable to heatCarotenoidWithout yellow and redPlantsWaterStable to heatChlorophyllGreen, brownPlantsLipid and WaterSensitive to heatHemeRed, brownAnimalsWaterSensitive to heatSource Cahyadi (2006)Tabl