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Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5) PowerPoint PPT Presentation


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Module 4.5. Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5). Objectives To make trainees aware of the importance of an accurate flow diagram and plant schematic to identify potential hazards

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Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5)

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Module 4 5

Module 4.5

Construct Flow Diagram& On-site Confirmation of Flow Diagram (Tasks 4 & 5)


Objectives and contents

Objectives

To make trainees aware of the importance of an accurate flow diagram and plant schematic to identify potential hazards

To enable trainees to construct an accurate and complete flow diagram and plan schematic

Contents

Preparing a process flow diagram

Preparing a plant schematic

On-site confirmation of flow diagram

Objectives and contents

Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram(Tasks 4 & 5)


Why flow diagrams

How can we anticipate problems?

By thinking through each step and identifying potential hazards and possible control measures

Constructing an accurate flow diagram is an important task in the HACCP system

Why flow diagrams?

Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram(Tasks 4 & 5)


A good flow diagram

Identifies all significant process steps used in production of specific product being considered

Process step definition – ‘A point, operation or stage in the food chain, from primary production to final consumption’

Enough detail to facilitate hazard identification without overburdening the plan

A good flow diagram

Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram(Tasks 4 & 5)


Constructing a flow diagram

Flow charts constructed on the basis of

Interviews

Observations

Blueprints or other documents

Model form provided

Constructing a flow diagram

Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram(Tasks 4 & 5)


Evaluating process steps

For each step, all relevant process data should be considered

All ingredients and packaging

Time / temperature history including potential for delay

Product recycle / re-work loops

Equipment design features

Evaluating process steps

Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram(Tasks 4 & 5)


Completing form 3 example of boia production

Completing Form 3 –example of boia production

Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram(Tasks 4 & 5)


What is a plant schematic

Diagrammatic representation of establishment showing

Product, ingredient flow

Employee movement patterns

What is a plant schematic?

Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram(Tasks 4 & 5)


Why a plant schematic

Aids in the assessment of potential for cross contamination

Plant schematic may include

Routes of potential cross contamination

Personnel routes

Area segregation

Flow of ingredients, packaging, waste materials

Why a plant schematic?

Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram(Tasks 4 & 5)


Sample schematic plant for production of currants

Co-operative shop

Finance / extension

office

Control

QC

Processing

lines

Indoor

storage

Staff entrance

Fumigation

chambers

Staff

changing rooms

Dispatch /

supplies in

Packaging

Receipt of

currants

Outdoor

storage

Packaged

product

Sample schematic –Plant for production of currants

Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram(Tasks 4 & 5)


On site confirmation

Draft flow diagrams and plant schematics must be confirmed by on-site inspection

All important process operations included

Movement of product and employees on the premises confirmed

On-site confirmation

Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram(Tasks 4 & 5)


On site confirmation1

Checks should be made at various times and through all operational periods

All members of the HACCP team should be involved in the confirmation of the flow diagram

Drafts adjusted according to findings of on-site inspection

On-site confirmation

Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram(Tasks 4 & 5)


Summary

We have looked at

Understanding the importance of flow diagrams and plant schematics

Preparing flow diagrams

Preparing a plant schematic

Confirming accuracy of diagrams

Next step: Applying HACCP Tasks 1-5

to green coffee production

Summary

Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram(Tasks 4 & 5)


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