Good Manufacturing Practices (GMP)

trade good Manufacturing Practices (GMP)3.1. IntroductionGMP the building blocks for HACCP. In several years, producer, retailer and industrialist habituate right(a) Manufacturing Practices (GMP) as appropriate method in order to produce good quality of forage. Food producers keep on developing GMP regulations. Now, it implements as prerequisite curriculum on HACCP system or food safety system.Good Manufacturing Practices should be selected and adopted before HACCP is implemented. Without the application of CGMP principles, an effective HACCP broadcast cannot be conducted. Furthermore, GMP must be applied to the development of sanitation standard operating procedures (SSOP). Compliance with specific GMP should be included as variance of HACCP. The argonas that should be addressed through CGMPs ar personal hygienics and other practices, buildings and facilities, equipment and utensils, and toil and make controls. CGMPs should be broad in nature (Marriot, 2007).There can har dly be HACCP without Good Manufacturing or Management Practices (GMP). Briefly, GMP is a description of all told in all the steps (which should represent good practice) in a processing facility, while HACCP is a documentation that the steps grievous to consumer health atomic number 18 under control (Arvanitoyannis and Theodoros, 2009)GMP application is as well(p) a basic part of Total Quality Management Program (TQMP). GMP application should be explain in briefly and clearly about problems and procedures on every stage on food processing.3.2. DefinitionGMP and SSOP ar interrelated and an important part of process control. CGMP argon the stripped sanitary and processing requirements necessary to ensure the production of wholesome meat. GMP is one of supporting program for implementation of HACCP system. GMP make food product have a good quality and safety it is in like manner make product widely acceptable for consumers in domestic and international market.establish on Min istry of Marine Affair and Fisheries Regulation (2007), GMP is the guideline on good prerequisite and production procedures on lean processing unit.GMP is a combination of the production and quality control, to ensure that food manufacturers or processing argon following the right step of its production line consistenly and spesifically. GMP refers to the regulation that firstly decl ard by the US Food Drug Administration (FDA) after macrocosm revised in 1986.GMP regulation is aimed to protect the consumer to avoid purchasing any dangerous or contaminated products. Its require a good quality approach of manufacturing and processing product to eliminate errors and failure. Nowadays, the function of GMP is getting more important as pre-requisite program of HACCP therefore it has to be implemented prior the HACCP system together with the application of SSOP.3.3. ScopeAccording to Darwanto and Murniyati (2003), on operational processing unit, company management should be check on pro cessing activities for evaluatinga. suitability, quality, and all input factor such as weight, food additives, ingredients, packaging, labeling etcb. control suitability and condition of manufacturing namely construction, maintenance, sanitation, operation, and equipments that argon drug abuse on fish processingc. fulfillment of end products requirements atomic number 18 quality, safety, healthy, and likewise composition and grade of quality on productd. staff checking on their health, hygiene and qualification.3.4. GMP components3.4.1. Location and Building Requirement3.4.1.1. LocationSeafood go down is consider of a suitable fixing. Some factors should be considered namely physical, geographical and infrastructure available. A plant must be adequate to(predicate) on a plot of adequate size, easy access on disco biscuitation by road, rail or water. An adequate of water should be available throughout the year. Seafood plants contain significant amounts of organic matter whic h must be removed before waste water is dangle into river or the sea. It also solid waste handling needs c atomic number 18ful or appropriate planning, appropriate space, must be available. The immediate physical surround of a seafood manufactory should be landscape and present on attractive view to the visitor. Shrubbery should be at least 10 meter away from factory building and a grass free strip covered with a layer of gravel should follow the outer protect of buildings (Huss, 1994).In addition, the factory location should be large enough for expansion and should be attractively landscaped with natural features such as tree retained wherever possible. Paved or asphalt discipline atomic number 18 needed in factory, car pack should be situated at a reasonable walking distance from the factories to flash back fumes and noise (Forsythe and Hayes, 1998).3.4.1.2. BuildingThere are several requirements for fish factories buildings. The materials that apply on building materials s hould be have the specific characteristics. There are specific characteristics such as non-porous, non-toxic, substantially cleaned, rodent proof, smooth 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 frameed and built for particular purposes with materials capable of withstanding various physical conditions. The principal factors to consider are hop up, cold, humidity, and vibration.On fish processing, interior surfaces should be smooth, non-porous, easily cleaned and not vulnerable to chemical attack by modern detergents and disinfectants, or able to sustain biological/microbiological growth.Good natural light and screened electric light must be provided. Paints and other surface coats should be non-toxic and not flake those that contain mould inhibitors must not come into contact with foods.Pipe work, drainage ducts, conduits for power supply a nd other channels should be tightly sealed where they pass through walls, floors and ceilings to prevent entranceway of vermin and insects (Huss, 1994). Overhead pipe work sometimes passes directly over process lines and water condensed on the pipes can drip on the underlying food and equipment (Forsythe and Hayes, 1998).Ventilation on fish factory have to efficient and ceiling should be constructed of and finished with materials that obviate condensation, paint flatting, and mould growth. The panel construction existence 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 certain situation. All wall angles, corners and junctions of walls and floors must be imperiously sealed and be rounded for ease of cleaning. Coving of the wall/floor junction of walls to a height of. C. 15 cm. Modern materials that are utilise on wall include polypr opylene and different PVCs. Suitable polymers and glass-reinforced PVC can be layered on a thin metallic surface with a facing 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 topping the cover with appropriate materials. These include epoxy, polyester or acrylic resins, chlorinated and styrene scarcelyadiene rubbers and bituminous paints and mastics. The resins have a number of advantages such as durable, easy to clean, good non-slip surface, smooth save became saturated and absorb water under water condition. Tiles can provide a relatively long lasting and impervious surface. However, there are weaknesses since they crack, superlative to be under run by water, and are ambitious to replace satisfactory (Forsythe and Hayes, 1998).Ideally, building have to impose no constraints on any process or plant layout. However, production line are sited in unsuitable buildings as an economic necessity. Construction of building can be nominate on reinforce concrete or steel frame. In the framed structure the external walls are essentially a skin design to protect force-out and equipment inside. It means 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, sooner straight through lines of product flow. Final or intermediate processes must be separate to avoid cross- defilement by raw materials.According to Kotschevar and Terrell (1977) in Forsythe and Hayes, (1998), there are eight principle in efficiency flow of work in food service area 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 eliminatedworker and materials should cover minimum distancesmaterials and to ols 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 will minimize recontamination of fish process or raw materials.The preparation areas for all raw materials and all product should be physically separated by appropriate walls. The movement of operators between the separate processing areas should be use of allocated colorise clothing and control by management.Facilities for washing hands with knee or foot operated hot water taps should be positioned at all walker entrances in food factories as well as in the toilets. Suitable liquid unperfumed soaps, barrier figure outs and disposable towels must be provided at all times, with counsel given also their proper use.Floors should be durable, smooth, easily cleaned and carefully insulated in addition, because of the proble m 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. digit layout of cold stores should aim at keeping the environment as constant a possible. Thus the entry of warm air should be minimized by providing in good order 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 Working 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 inert to the food under the condition of use and must not migrateall surfaces in contact with food must be smooth and non-porous so that tiny particles are not caught in microscopic surface crevices and become grueling 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 arranged 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 prevent 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 utilize in food processing are Stainless 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 bloodless spots, especially within the operation chamber and associated pipe work. Bolts and clips should be attached 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 urine flumesDirectionVertical up***Vertical down***Incline up***Incline down****Horizontal*** FrequencyContinuous****Intermittent** Location servedPoint****Path***Limited areaUnlimited area** HeightOverhead****Working height****Floor level****Underfloor***MaterialsPacked****Bulk******Solid******Liquid** ServicePermanent**** * pro tempore**From Brenan et al (1976) in Fellow, P.J. (1990)3.4.2. Operational 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 freshness. It enables differences in texture, flavor, and taste to be determined, and subsequently the usefulness of the raw material. Sensory properties change during storage from the desired very high standard, through neutral or average, and finally to 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 most difficult step is to determine an intermediate state in which the fish is not entirely fr esh. 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 powers of quality in the case of raw fish. For cooked fish, smell is the most 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 Anonymous (2002), checking the following at receipt will keep 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 transport vehicle,a record of the species, ha rvest date and location, and suppliers name, andvisual quality criteria.Even if quickly frozen after catching, frozen seafood will not keep indefinitely. bacterial activity ceases below about -10oC, but chemical and biochemical changes (enzymes, oil oxidation, and dehydration) will still occur. These changes may bring about slow irreversible changes in odor, flavor, and appearance. For long term freezer storage, it is recommended that a temperature of -30oC is keep (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 and ProcessingFish and shellfish are considered to be among the most perishable foodstuff. To keep fish cool, packing in ice is use this methods is avoids the possible action of the temperature dropping to low with the concomitant 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 spoilage 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 ice. Fish properly iced will cool rapidly and will retain quality for 1 to 2 weeks, depending on the species. Ease handling, reduction of weight loses, and elimination of bruising are advantages to be considered in short-term storage in refrigerated seawater (Shapton and Shapton, 1991).Since prawn 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 shrimp on the ships deck, in handling, and from iced used during their storage. The prevention 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 unhealthful bacteria, histamine producing bacteria and spoilage bacteria. 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 preservatives, nutritional additives, flavoring agents, food coloring agents, texturizing agents, and miscellaneous additives (Branen and Bragerty, 2002).a. PreservativesThere are basically three 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 caustic (E330), and sodium sulte (E221) are the most commonly used additives in this kinsfolk (Branen and Bragerty, 2002).b. Chemical preservative sThe 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 lowest pH set of food and ineffective at neutral 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 recent years. This imparts a red coloration to the meat simi lar to fresh meat (Betty and Diane, 1987).c. Nutritional AdditivesNutritional additives have increased 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 restore nutrients lost in processing or to enhance the overall alimentary 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 integrity of the tolerant 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 oxidative damage and reduce the risk for age-related disorders by prev enting 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 soya protein also are sometimes used as nutritional additives, although they are most commonly used as texturizing agents. type additives have seen increased popularity in recent years with the increase in consumer interest in dietary fiber. Various cellulose, pectin, and starch derivatives have been used for this purpose.d. change AgentsMost 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. Natural coloring made from plants and animals (Table 3.4.). Synthetic coloring made from chemical substances (Table 3.5.).e. Flavoring 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 window glass that are allowed for using in food processing (Indonesian Ministry of Health Regulation No. 722/Menkes/Per/IX/88)NoChemical PreservativesKinds of FoodMaximum dose1Sulphur dioxideMarmaladeTomato pasteSugar PowderPowder dextroseSugarVinegarSyrupWineGrapeSausageDried umber expressGelatin ascorbic acid mg/kg350 mg/kg20 mg/kg70 mg/kg70 mg/kg70 mg/kg70 mg/kg200 mg/kg450 mg/kg150 mg/kg1 g/kg euchre mg/kg2Potassium Bisulphate cut friesFrozen shrimpPineapple essence rend50 mg/kg10 mg/kg (raw) 30 mg/kg (cooked)50 mg/kg3Potassium MetabisulphateFrench friesFrozen shrimp50 mg/kg100 mg/kg4Potassium nitrateMeat cease500 mg/kg50 mg/kg5Potassium nitriteMeat feed125 mg/kg50 mg/kg6Potassium sulphateFrench friesFrozen shrimpPineapple essence evoke50 mg/kg100 mg/kg500 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 modif y the overall texture or mouth feel of food products. Phosphates and colewort conditioners are other chemicals that play a major post in modifying food texture. Lecithin and mono- and diglycerides as well as several synthetic derivatives. The primary 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 desired 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 defend with protein and/or starch and modify the water-holding capacity of these natural food components (Branen and Bragerty, 2002).Benefits of AdditivesThere are obviously many recognized 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 potential direct toxicological effects of additives. Cancer and reproductive problems are of primary concern, although there is no direct evidence linking additive consumption with their event 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. Organic 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 sauceSoft drink cucumber pickleoleoPineapple essence extractOther foods600 mg/kg600 mg/kg1 g/kg1 g/kg1 g/kg1 g/kg2Propionic acidCheeseBread3 g/kg2 g/kg3Sorbic acidCheese3 g/kg4Benzoic PotassiumMargarinePineapple essence extractDried apricotJam 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 coff ee extractTomato paste, essenceOther food except meat, fish, fowl250 mg/kg450 mg/kg1 g/kg1 g/kg9Natrium benzoateJam and jellySoy sauceSoft drinkOther foods1 g/kg600 mg/kg600 mg/kg1 g/kg10Natrium propionicLook at on propionic acidLook 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 characteristicGroup twistSourcesSolubilityStabilityCaramelBrownCooked sugarWaterStableAnthosianineOrange, RedBluePlantsWaterSensitive to heat and pHFlavonoidWithout yellowPlantsWaterStable to heatLeucoanthocianineColorlessPlantsWaterStable to heatTanninColorlessPlantsWaterStable to heatBatalineYellow, redPlantsWaterSensitive to heatQuinonYellow-blackLichenWaterStable to heatXanthonYellowPlantsWaterStable to heatCarotenoidWithout yellow and redPlantsWaterStable to heatChlorophyllGreen, brownPlants lipid and WaterSensitive to heatHemeRed, brownAnimalsWaterSensitive to heat Source Cahyadi (2006)Tabl