CCP-HACCP For Instant green tea powder

MINISTRY OF EDUCATION AND TRAINING
NONG LAM UNIVERSITY – HO CHI MINH CITY
FACULTY: CHEMICAL ENGINEERING AND FOOD TECHNOLOGY
Class: DH18TP
----

INSTANT GREEN TEA POWDER
INSTANT DRINK

GROUP 5 - MEMBERS
Nguyễn Thị Thanh Vân

Hanna

Võ Nguyễn Thục Trinh

Rina

Đỗ Hồng Ánh Mai

Mia

Nguyễn Thu Hiền

Helen

Đỗ Thị Yến Ly

Pine

Bùi Thiên Lộc

Thomas

Hồ Thanh Tuyền

Jena

Nguyễn Thị Kim Tuyền

Kitten

Trương Thị Thanh Xuân

Xuan

December 2021 - Ho Chi Minh city


TABLE OF CONTENT

TABLE OF CONTENT ............................................................................................... 2
INTRODUCTION ........................................................................................................ 3
HACCP TEAM ............................................................................................................. 4
PRODUCT DESCRIPTION AND INTENDED USE ............................................... 5
FLOW DIAGRAM ....................................................................................................... 6
PLANT LAYOUT......................................................................................................... 7
PROCESS STEP DESCRIPTION .............................................................................. 9
RISK ASSESSMENT AND CCP, OPRP DETERMINATION ............................. 12
HACCP PLAN ............................................................................................................ 18
OPRPs PLAN .............................................................................................................. 19

DISCUSSION AND CONCLUSION ........................................................................ 21
1. Discussion: ........................................................................................................... 21
Non-CCP hazards: .............................................................................................. 21
CCP hazards: ...................................................................................................... 22
Non-OPRP hazards: ........................................................................................... 23
OPRP hazards: ................................................................................................... 23
2. Conclusion: .......................................................................................................... 25
REFERENCES ........................................................................................................... 25

2


INTRODUCTION
HACCP is an abridgment of the Hazard Analysis Critical Control Point system, which
is tantamount to food safety management. Essentially, it is “a system which identifies,
evaluates and controls hazards which are significant for food safety’’. It is a system that
gives confidence that food safety is being controlled effectually. The hazards that need
to be analyzed and controlled are biological, chemical, and physical hazards from raw
material production, procurement, and handling, to manufacturing, distribution, and
consumption of the finished product or anything that could go wrong regarding product
safety and implements controls subsequently to ensure that the product will not cause
harm to the consumer.
OPRP as a control measure identified by the hazard analysis as necessary to control the
likelihood of introducing food safety hazards and contamination or increase of food
safety hazards in the product or the processing environment. OPRP is definite action
relating to the process, although not being critical for food safety, but they are essential
in reducing the probability of specific hazards occurring.
Turning green tea leaves into instant green tea powder is a complicated process that
included many stages of preparing as well as processing. To achieve good products
quality and food safety and hygiene. Mainly hazards biological from E. Coli bacteria,

Salmonella, Coliform, etc... and other physical hazards, chemistry, allergies need to be
minimized to the maximum. Research plans for the Hazard Analysis, Critical Control
Point (HACCP), and OPRP systems for pre-processing and processing at instant green
tea powder factories need to be discussed, researched, implemented, and focused,
followed clearly to minimize the unfortunate threat to products quality.

3


HACCP TEAM
No.

Name

Position

Responsibility

1

Hanna

Plant Manager

HACCP team
leader

2

Helen

QA Manager

Committee

3

Jena

Production Manager

Committee

4

Kitten

QC Manager

Committee

5

Mia

Engineering
Manager

Committee

6

Pine

Packaging supervisor

Committee

7

Rina

Raw materials
reception manager

Committee

8

Thomas

AG Supervisor

Committee

9

Xuan

Warehouse operative

Committee

4

Skill/ Experiences
BSc. - Food Science
MSc. - MBA
10 years of experience
GMP, HACCP, ISO
certificate
BSc. - Food Sci & Tech.
GHP, HACCP training
3 years QA experience
BSc. - Food engineering
GHP, HACCP training
5 years QA experience
BSc. – Chemistry
GHP, HACCP training
4 years QA experience
BSc. - Engineering
GHP, HACCP training
5 years QA experience
BSc. –Control
Engineering and
Automation
GHP, HACCP
5 years of experience
BSc. -Food Science
HACCP certificate

3 years of experience
BSc. - Food Sci & Tech.
GHP, HACCP training
3 years QA experience
BSc. -Food Science
GMP, HACCP, ISO
certificate
4 years of experience


PRODUCT DESCRIPTION AND INTENDED USE
1. Product name / Group product

Instant green tea powder

2. Composition

-100% pure green tea leaf powder
-No additives
3. Important product characteristics - pH from 7-10
of end-product (e.g., pH, aw,
- Not an allergen
Allergen, etc.)
- 60% polyphenols (19.98 ± 1.15 mg/100 g dry
leaf weight)
4. How the product is to be used
- 1 teaspoon powder with 200ml warm water
(60 - 80℃), stir well to mix with sugar, milk to
drink better.
- Make a face mask.

5. Packaging (net weight, etc.)
- Packed with aluminum foil sachets in a paper
box.
- Net weight: 40g (2g x 20 sachets)
6. Shelf-life and storage condition - Shelf-life: 2 years
- Storage: Please store tea powder in a dry place
at room temperature and keep away from
direct sunlight.
7. Where the product will be sold
- Supermarkets, markets
- Retailer
- E-commerce platform
8. Labeling instructions
Nutrition information, serving size, EXP,
ingredients, manufacturing information,
imported by the importer.
9. Special distribution control
No physical damage, avoid placed with high
temperature or humidity
10. Consumer group
All ages except children under three years

5


FLOW DIAGRAM

Information: Tea powder is packed in aluminum foil sachets with a
weight of 2g per sachet (20 sachets per box). The product contains 100%
pure green tea leaf powder, does not have any allergen and is suitable for

all ages except children under 3 years old. This product can be used to
make soft drinks (1 teaspoon for 200ml warm water) and can be used as
a mask (mixed with yogurt, honey in a 1:1 ratio). Nutrition information,
serving size, EXP and ingredients are declared on label. The storage
condition: cool, dry place and avoid physical damage.
6


PLANT LAYOUT

To avoid cross-contamination in food manufacture, the factory must be designed and
organized in accordance with HACCP and must adhere to the one-way rule from input
materials to final products. As a result, the factory is divided each level of cleanliness
into production and non-production areas.

I. Production area
Reception raw material (incoming materials and raw materials store): Raw products
are in the proper conditions (avoid places with high temperature or humidity) and
method so as to maintain quality and reduce loss of the material during storage.
+ Incoming raw materials where the company imports raw materials including tea
leaves, water, paper box, and aluminum foil sachet from distributors.

7


+ Raw material storage room is used for storing, checking and classification the quality
of raw materials, as well as preliminary processing before materials, go into processing.
Processing area
The processing area plays an important role in the company in which raw materials (tea
leaves) are directly variable into the final product (instant tea powder). Therefore, the

area must be of high quality in order to obtain safe and high-quality products according
to GMP and HACCP standards.
Packaging area
Applying proper packaging methods and ensuring hygienic conditions will reduce the
risk of contamination with hazards in the packaging process to a minimum. After
packaging, the products are checked once again to ensure there is no mistake on the
outlook and no metal contamination in each product.
Packaging warehouse
Packaging warehouse is used to store packing materials to avoid cross-contamination
and to expand space for the packaging process
Finished products warehouse
Finished product warehouse is where the products are stored as well as get ready for
export.

II. Non-production area
Lab
It is used for microbiological testing in tea powder and other related matters, followed
by the administration.
Freezing system
This system helps to control and maintain the ideal temperature for freezing steps
Water treatment system
The purpose of a water treatment facility is to make water potable and palatable while
also ensuring that there is a sufficient supply of water for the company's water needs.
Raw water is pumped, or flows, to a treatment facility. Once there, the water is pretreated to remove debris such as leaves and silt. Then, a sequence of treatment processes
- including filtration and disinfection with chemicals or physical processes - eliminates
disease-causing microorganisms.

8

Clean in Place system
In food processing, insufficient cleaning can result in reduced efficiency, contamination
in final product, and energy losses. To optimize widely implemented clean-in-place
(CIP) systems, it is critical to understand the influence of the interactions between
surfaces, fouling, and chemical agents on the efficiency of the cleaning process (AvilaSierra, Zhang, & Fryer, 2019). This system helps to clean the interior surfaces of pipes,
vessels, types of equipment, filters without major disassembly.
Waste storage
Proper waste management is important to protect human health and the environment,
so this area should be located in the farthest location to ensure hygiene and easily treat
the waste when it goes out of the environment.
Employee canteen and relaxing area, packing area for employee's welfare and
visitor parking area for the welcome.

PROCESS STEP DESCRIPTION
#
1

2
3
4
5

6

7

Processing steps/
Incoming
Process step description
materials

Paper box
Paper boxes are transported to food factory by trucks
receiving
After harvesting, it should be transported quickly to the processing factory
Tea
by trucks with specialized containers or by trucks carrying bags containing
leaves receiving
tea leaves. Before being put into the warehouse, it must be carefully checked
the quality assessment criteria.
Water receiving Water is received from a water factory and stored in large water tanks.
Aluminum
Aluminum foil sachets are delivered from the supplier and stored in the
foil sachet
warehouse
Leaves are washed to remove residue, sand on the surface of tea leaves. The
Washing
water used to wash the tea leaves has a temperature of 25-30º C and drains.
Firstly, the tea particles need to be made into small particles to increase the
surface area contact of tea particles to the solvent to extract more soluble
Rolling/Grinding solid from the structure of the particles and not to impair the extraction yield.
Normally, the range of the particles size from around 100 micrometers to
around 180 micrometers is optimal.
Drying: High-temperature drying is not desirable for water-soluble
components of green tea contain very easily oxidizable components,
Drying (Steaming)
such as ascorbic acid and catechins. Therefore, such drying methods as
vacuum drying, freeze-drying, and spray drying are considered suitable.
9

8

9

10

11

12

Steaming: The method comprises the following steps of pre-dissolving the
tea raw materials such as tea leaves, tea stems, and tea residue, performing
steam explosion under the pressure of 0.8 to 1.8MPa, keeping the pressure
for 0.5 to 5 times, collecting the steam explosion material, and performing
purification, concentration and drying according to the state of a steam
explosion system to produce the instant green tea powder.
Using the hot extraction, the size of particles should be maintained larger,
usually more than 500 micrometers to 800 micrometers. The type of solvent
used for this step should be low cost, safe for human health, safe for the
environment. So now people more refer to use water or ethanol. However,
Extraction
ethanol is much more expensive compared to water. So, people tend to use
hot water with a temperature from 70oC to 90oC to increase the extraction
yield of the soluble solid from the materials. The ratio between the dry
matters (tea particles) to the solvent should be in the range of 1:2 to 1:10
mean 1 portion in weight of the dry matters and 2 portions in weight of the
solvent until 10 portions in weight of the solvent.
Filtration
At this step, the mixture of solid and liquid matters will be filtrated to
remove extraneous objects or solid materials from the extraction step.

The main purpose of this step is to utilize some ways to recover or collect the
volatile through the technique of condensation. People use water vapor flow
to move this volatile together with water vapor through another lower
Aroma Stripping temperature area, with the absolute humidity if it moves to the lower
temperature area, the condensation occurs. When condensation occurs, water
vapor will be condensed into the liquid form and the volatile will be
dissolved in the solution. This solution will be remixed with the input fluid
before the freeze-drying step.
Using the osmotic evaporation (OE) process: The effect of the OE process on
the content of phenolic compounds and antioxidant activity was evaluated.
The concentration process was carried out in a hollow fiber membrane
contactor with an effective surface area of 0.54 m2. The tea extract was
Concentration circulated through the shell side of the contactor, while a concentrated
osmotic solution (CaCl2 5 M) was circulated inside the fibers. It is possible
to reach a tea concentration of 40% (w/w) in 5h, with a constant water flux
and without losing the phenolic content and antioxidant potential in most
teas.
During the freezing stage, the material is cooled below its triple point,
the lowest temperature at which the solid, liquid,
and gas phases of the material can coexist.
To facilitate faster and more efficient freezePre-Chilling
drying, larger ice crystals are preferable. To produce larger crystals,
(Freezing)
the product should be frozen slowly.
Temperature: -18OC
Time: 2 hours
Method: Using a cryogenic freezer upstream of a spiral freezer.
10

13

14
15
16

17

18

Freeze drying, also known as lyophilization or cryodesiccation, is a lowtemperature dehydration process that involves freezing the product, lowering 
pressure, then removing the ice by sublimation.  Freeze drying is particularly
useful for producing granules for instant tea and tea extracts. The freezedrying process allows the substances in the tea to retain their desired, useful
Freeze Drying properties, while, at the same time, the product remains highly soluble. A
freeze-dried tea dissolves extremely easily and quickly in water, but with that
authentic taste of tea expected by the consumer.
Temperature: -35oC
Time: 8 hours
Method: using a freeze dryer and a vacuum pump.
Instant green tea After going through the above steps, the tea leaves have been made
powder
into instant green tea powder.
Packaging is the stage soluble tea powder that will be packed into aluminum
Packaging
foil sachets.
After placing the tea into the bag.
Sealing by heat
Place the top of the between the seal bars.
sealer
Press down gently for approximately 2-3 seconds and release.

After packing and sealing, the product will be brought along the conveyor
belt through the metal detector and if it detects that the metal fragment
exceeds the allowable level, the machine will signal and stop the conveyor. If
Metal detector
no metal fragments are detected, the product is removed from the metal
detector by a conveyor belt.
Metal detector testing frequency: 60 minutes / 1 time.
After packing, the product is placed on a tray that passes through the paper
boxing system. The product is put into a paper box, then it will go through a
Boxing/ Labeling glue machine to glue the box.

11


RISK ASSESSMENT AND CCP, OPRP DETERMINATION

#

Processing Steps

Identified Hazards
(B/C/P/A)

Control measures

S

O

1 Paper box receiving B: -

-

-

-

C: -

-

-

-

P: Dented, damaged paper
box

- Checking the quality of
the receiving paper box
carefully

L

L

-

-

A: 2 Tea leaves
receiving

B: Salmonella, E. coli

H

P: Sand, gravel.

L

B: E. Coli, Coliform

C: Pesticides, toxic
substances
P: Impurities

A: 4 Aluminum
B: foil sachet receiving
C: -

5 Washing

H

C: Chemical contamination - Controlled by GMP/ GAP
can happen because of
environmental pollution,
inappropriate use of
agrochemicals, sabotage,

adulteration, residues of
pesticides and pesticides.

A: 3 Water receiving

- Controlled by GMP/GHP

- There is a stage to remove
impurities in the material
(sifter screen, clean the
fresh tea place...)
-

H

- Controlled by GMP and
SSOP

H

-

M

M

M

-

-

-

-

A: -

-

Changing the water
everyday batch of washing

H

-

L

B: Salmonella,
E. coli, Coliform.

M

M

P: Scraps of aluminum foil Check the quality and
hygiene of the packaging
according to GMP
-

M

-

- Check the quality of the
water source in time
-Controlled by GMP

Use a filter

-

L

-

M

M

12

Sig.
Q1 Q2 Q3 Q4 Q5 CCP/OPRP Subsequence
Hazard
No.
step
HACCP - - OPRP
- - - HACCP - - OPRP

- - - Mi
HACCP ✓   OPRP

✓



-

-

Ma

HACCP
OPRP
HACCP

✓



✓

✓

Ma

OPRP
HACCP

✓
✓






-

OPRP

✓

✓

✓

✓  OPRP-1(C)

-

HACCP

✓





-

-

5

OPRP

✓



-

-

-

-

-

HACCP
OPRP
HACCP

✓





-

-

-

-

OPRP

✓

✓



-

-

-

-

Ma

HACCP

✓





-

-

-

Ma

OPRP
HACCP

✓
✓

✓


✓





OPRP-2(C)

-

-

OPRP
HACCP
OPRP
HACCP
OPRP
HACCP
OPRP
HACCP

✓
✓

✓





-

-

-

-

OPRP

✓



-

-

-

-

-

HACCP
OPRP
HACCP

✓





-

-

-

-

-

Mi

Ma

Mi

Ma

-

-

-

-

-

13

-

-

-

-


C: P: Sand, dust, insect
fragments.

6 Rolling/Grinding

-

M

H

✓



-

HACCP
OPRP
HACCP

✓





OPRP

✓

✓

HACCP
OPRP
HACCP
OPRP
HACCP
OPRP
HACCP

✓

OPRP

Mi

Cr

Ma

-

-

-

-

B: -

-

-

-

-

P: Sand, dust

-

-

Good implementation of
GMP, SSOP.
Extraction will remove all
impurities.

M

A: Tea dust (food allergy in Use N95, N99 Respirators
sensitized individuals)
or air filter masks

H

Drying/Steaming B: Escherichia
coli and Salmonella.

The organism’s heat
sensitivity makes it possible
to eliminate with LTHT
treatment (low temperature
and high temperature)

M

P: Iron particles.

To remove iron, magnets
are often placed at the
mouth of the dryer, belt, and
color sorter to catch iron
particles in different stages
of the process.

M

-

-

B: Salmonella, E. coli,

Cryptosporidium
parvum, Coliform.

C: Epidallocatechin-3gallate, chlorine.

Clean water testing, water
treatment operation, water
analysis before extracting

Control the concentration of
substances to the minimum
allowed.

M

L

H

C: Chemical contamination To keep clean and, where
can arise because of
necessary after cleaning, to
environmental
disinfect, in an appropriate
pollution, lubricants from tea manner, facilities,
processing machinery,
equipment, containers.
fumigant residues from the Use the right amount of
fumigation of containers
lubricant for machine

maintenance

A: 8 Extraction

Proper implementation of
GMP
Clean and maintain the
machine regularly

-

✓

A: -

C: -

7

-

OPRP

H

M

M

-

L

L

M

L

13

Ma

Ma

Ma

Mi

Mi

-

-

-

-

-

-

-

✓



-

OPRP-3(P)

-





-

-

-

-

-

✓



-

-

-

-

-

HACCP

✓





-

-

-

-

OPRP

HACCP

✓
✓



-

-





-

-

OPRP

✓



-

-

-

-

-

HACCP

✓





-

-

-

OPRP

✓



-

-

-

-

HACCP

✓





-

-

-

OPRP

✓



-

-

-

-

-

HACCP
OPRP
HACCP

✓





-

-

-

-

OPRP

✓



-

-

-

-

-

HACCP

✓





-

-

-

OPRP

✓



-

-

-

-

-

-

-


P: Sand, Stones, …

A: 9 Filtration

B: L. monocytogenes.

-

H

M

-

M

P: -

-

B: Microbial (Salmonella
spp.) growth

M

M

C: Abuse of artificial
- Training staff to follow
flavoring leads to exceeding strict guidelines.
the allowable threshold.
- Strengthen supervision in
this stage.
- Do not abuse artificial
flavorings.

-

-

H

L

-

L

-

- Perform regular cleaning
and maintenance of
machines to avoid crosscontamination.
- Follow proper cleaning
and sanitizing procedures.

A: 11 Concentration

-

B: E. coli microorganisms, Clean the filter properly.
yeasts, molds.
Select filter core with a
small size to filter
microorganisms.
C: Chlorine, strange odors: Choose a good filter
Poor quality charcoal filters material with high
will absorb organic
absorption capacity.
compounds less efficiently. Replace the filter layers as
prescribed (6 months/1
time)
P: Insoluble residue, foreign Clean the filter regularly for
matter. Improperly cleaning normal filtration.
the filter
A: -

10 Aroma Stripping

GMPs: using water for
extracting.

M

L

-

-

-

Ma

Ma

Mi

Mi

-

- Take great caution when
modifying the temperature
- Inform the factory
manager to temporarily
suspend production to
establish on-site corrective

actions.

H

C:
- Monitor cleaning and
- Contaminants such as
checking status at the
lubricants from the machines beginning and end of shifts
that are not hygienic.
every day
- Training workers again
about equipment hygiene
knowledge.

H

L

Mi

H

L

Mi

- The leak of CaCl2 from the -Checking and maintaining
fibers of the contactor in
the stability of the

osmotic evaporation
contactor.
process.

L

Mi

14

Mi

HACCP

✓





-

OPRP

✓



-

-

HACCP
OPRP
HACCP

✓



✓

OPRP

✓

✓

HACCP

✓

OPRP

-

-

-

-

-

✓

-

-

13



-

-

✓

-

-

✓

✓



-

HACCP

✓





-

OPRP

✓



-

-

HACCP
OPRP
HACCP

✓





OPRP

✓



HACCP

✓

OPRP

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-





-

-

-

✓



-

-

-

-

HACCP
OPRP
HACCP
OPRP
HACCP

✓





-

-

-

OPRP

✓



-

-

-

-

HACCP

✓





-

-

-

✓





-

-

-

-

-

-

-

-


12 Pre – chilling
(Freezing)
(-18oC/2 hour)

P: -

-

-

-

-

A: -

-

-

-

-

B: L.
-Perform regularly cleaning
monocytogenes, Salmonella and maintenance of
machines to avoid crosscontamination.
- Follow proper cleaning
and sanitizing procedures.
- Humidity control is
extremely important.

H

C: Mycotoxin

Source control: COA,
AVL)

Processing control
Control GMP, especially
GHP personal hygiene
(personal cleanliness)

M

-

-

P: A: 13 Freeze Drying
(-35oC/8 hours)

-

B: L.
- Perform regularly cleaning
monocytogenes, Salmonella and maintenance of
machines to avoid crosscontamination.
- Follow proper cleaning
and sanitizing procedures.
- Humidity control is
extremely important.

C: Chemical
contamination lubricants
from the machine.

P:

- Dust form machines
- Electrical problems lead to
damage to machinery and
affect product quality.

- Do regularly cleaning and
checking of the machines to
prevent leaking lubricants.

- Do regularly cleaning and
maintenance of machines to
avoid dust and soils.
- Follow proper cleaning
and sanitizing schedules.
- Ensure sufficient power
supply for machines.

M

L

-

-

-

H

M

L

L

L

M

15

Ma

Mi

Ma

Mi

Mi

OPRP

✓



-

-

HACCP
OPRP
HACCP
OPRP
HACCP

✓



✓

✓

OPRP

✓

✓

✓



HACCP

✓





-

OPRP

✓



-

-

HACCP
OPRP
HACCP
OPRP
HACCP

✓

✓

-

-

OPRP

✓

✓

✓

✓ ✓

HACCP

✓





-

OPRP

✓



-

-

HACCP

✓





-

-

-

-

-

-

-

-

-

-

13

OPRP-4(B)

-

-

-

-

-

CCP- 1
(B)

-

-

-

-

-

-

-

-

A: 14 Instant green tea
powder

B: Mold: Aspergillus
ochraceous
C: P: Impurities of metal
samples.

A: 15 Packaging

B:
- C. botulinum, E.
coli, Salmonella from
workers, mold

C: -

P: Impurities (metal,
jewelry)
A: 16 Sealing by heat
sealer

B: Growth of
microorganisms (mold)

- Destroy by temperature
control
packing condition
-

-

-

L

L

-

- Use a magnet suction
machine/detector to remove
pieces of metal.

H

-

-

M

-

M

L

OPRP

✓



-

-

HACCP
OPRP
HACCP

-

-

-

-

-

-

✓





-

OPRP ✓
HACCP OPRP
HACCP ✓




✓

✓

-

OPRP

✓



-

-

HACCP
OPRP

-

-

-

-

HACCP

✓





-

OPRP

✓

✓

✓ ✓

-

HACCP

-

-

-

-

Mi

OPRP
HACCP

✓





-

OPRP
HACCP
OPRP
HACCP

✓
✓

 - -  ✓



OPRP

✓

✓

✓

HACCP

✓



OPRP

✓

HACCP
OPRP
HACCP

Mi

Ma

Mi

- Controlled by GMP/GHP
- Store the package in a dry
place and check the package
regularly

-

Check the quality of the
packaging carefully before
use
- Regularly clean and check
the heat-sealing machine

-

-

L

L

-

-

H

M

Ma

- Workers must follow the
right operation; check and
remove the incomplete
sealed products.

-

-

-

-

-

-

-

17

-

-

-

-

-

-

-

-

-

 OPRP-5(B)

-

-

-

-

-

-

-

CCP-2
(B)

-

✓ ✓

-

-



-

-

-



-

-

-

-

-

✓





✓



-

-

-

-

-

-

-

-

-

-

-

-

- Control the humidity of
the air
C: Chemical contamination Do regularly cleaning and
lubricants from the machine checking of the machines to
prevent leaking lubricants.

L

P: Impurities (jewelry,
sands, ...)

L

A: -

Controlled by GMP

-

L

L

-

16

Mi

Mi

-


17 Metal detector

B: -

-

-

-

-

C: -

-

-

-

-

P: Metal fragments.

A: 18 Boxing/Labeling

B: - Bacillus spp.,
Clostridium spp.,
Staphylococcus spp.
- Bacteria or mold

C: P: A: -

- Products are put through
metal detectors to remove
product packages containing
metal.
- Periodically, check the
metal detector by QC

L

-

-

- Controlled by GMP/GHP
- Clean and maintain the
machine regularly
- Place the product in a dry
place

-

H

-

M

L

-

-

-

-

-

-

S-Severity, O-Occurrence, Sig. Hazard (Cr = Critical, Ma = Major, Mi = Minor)

17

Ma

-

Mi

-

OPRP
HACCP
OPRP
HACCP
OPRP
HACCP

✓

✓

-

-

OPRP

✓

✓

✓

HACCP
OPRP

-

-

HACCP

✓

OPRP

HACCP
OPRP
HACCP
OPRP
HACCP
OPRP

-

CCP-3
(P)

-

✓ ✓

-

-

-

-

-

-





-

-

-

✓

✓

✓

✓

-

-

-

-

-

-

 OPRP-6(B)

-

-

-

-

-


HACCP PLAN
CCP No.
CCP- 1
(B)

Significant
hazards
B: L.
monocytogene
s, Salmonella

Freeze

Drying

Control measures

Critical
limits
(CL)

- Perform regular cleaning and - CL:
maintenance of machines to
35oC/9
avoid cross-contamination.
hours
- Follow proper cleaning and
sanitizing procedures.

(-35oC/8
hours)

- Humidity control is
extremely important.

- OL:
37oC/9
hours

Monitoring Procedure:
Corrective Action

Verification

Records

(What/How/Frequency/Who)
- What: Microbiological testing
for machinery and equipment
- How: Manage time, temperature,
and humidity appropriately during
the freeze-drying process. Taking
samples for microbiological
testing after each batch of frozen
tea concentrate
- Frequency: Drying conditions
must be checked regularly.
Equipment and tools must be
cleaned before and after use. All
of them should be recorded on the
checklist for easy tracking

Process:
- Isolate the batch of frozen
tea concentrate contaminated
with microorganisms

Microbiological testing
after each batch of frozen
tea concentrate

A-001

- Check the machine's
operating status and
humidity of the air before
starting work

A-002

- Determine the cause of
microbial contamination
during the drying process and
retrain the line operators if
necessary
Product:
- The product is destroyed or
used for other purposes

- Who: The workers in the factory
CCP-2

B: Growth of
- Regularly clean and check
microorganism the heat-sealing machine
(B)
s (especially
- Workers must follow the
Sealing by mold)
right operation; check and
heat sealer
remove the incomplete sealed
products.

The
product
must be
completel
y and
properly
sealed

- Control the humidity of the
air

- What: Monitor the operating
capacity of the heat-sealing
machine and the humidity of the
air during sealing
- How: Check the moisture in the
sealing area. Visually check that
the product is completely sealed
- Frequency: Everyday

-Train operators for proper
operation
-Stop the sealing process if
the product is not completely
sealed
-Isolate the product if it is not
completely sealed and left out
for too long

-Finished product
inspection in each batch

- Who: Operator or supervisor
CCP-3
(P)
Metal
detector

P: Metal
fragments

Products are put through
metal detectors to remove
product packages containing
metal.
Periodically, check the metal
detector by QC.

No metal
fragments
detected

- What: The product for the
presence of metal fragments.

- Identify the source of the
metal found in the product
and fix the damaged
equipment.

- How: Visual examination for the
presence of an operating electronic
- Correct operating
metal detector, magnet,
procedures to ensure that the
intact screen, or flotation tank.
product is not processed
- Frequency: Continuous
without metal detection.
monitoring by the metal detection
- Rework to remove metal
or separation device itself.
fragments from any product
- Who: Visual checks to ensure
rejected by the metal
that the device is in place
detector.
and operating may be performed
by any person who has an
understanding of the nature of the
controls.

18

- Check the metal detector
using validated sensitivity
standards daily, at the start
of production, every 4
hours during operation.

- Conduct a validation
study to determine
appropriate settings for the
metal detector
- Develop metal detector
sensitivity standards

A-003


OPRPs PLAN
OPRP
Significant
Control measures
No.
hazards
OPRP-1 C: Chemical
Raw material quality check
(C)
contamination
can happen
because of
environmental
pollution,
inappropriate
use of
agrochemicals,
sabotage,
adulteration,
residues of

pesticides and
pesticides.
OPRP-2 C: Pesticides, - Controlled by GMP and
(C)
toxic substances SSOP

Monitoring Procedure:
(What/How/Frequency/Who)
Residues of What: Check the content of
pesticides pesticides in the tea leaves
must meet
the
How: Sampling to measure the
standards of indicators in tea leaves
Circular
50/2016/TT- Frequency: 6 months/time
BYT
(Vietnam) Who: QC
Criteria

Take a
water
sample
before use
for testing

What: Disinfect water with UV
rays or OZONE, equipment
sanitation
How: Equipment, tools, and

containers that used to contain the
receiving water must be cleaned
and disinfected to make sure they
are free of harmful substances

Corrective Action

-Test the raw material
Material
quality 6 months/time.
check sheet
-QC manager checks the
result sheets.

- Determine the cause of
contaminated water source
-Treat or dispose of water
source
- Change new water source

- Make a diagram of the
Water
water supply system.
receiving
- Control the operation of
report
the system to maintain
good operation of the
treatment system, protect
and prevent the water

source from the risk of
contamination.
- Checking water quality:
planning and taking test
samples, handling
problems when having
results.

Who: QC, workers.
- Good implementation of
GMP, SSOP.
- Clean and maintain the
machine regularly

The
operating
capacity of
the machine
during the
process
must meet
the cleaning
of leaves

OPRP-4 B: L.
- Perform regular cleaning - Time,
(B)
monocytogenes, and maintenance of
temperature
Salmonella

machines to avoid crossof precontamination.
chilling
- Follow proper cleaning and must be
sanitizing procedures.
properly.

Records

- If the criteria exceed the
allowable limit, stop
production, isolate the batch
of raw materials, contact the
supplier to return the goods.
Recall products
manufactured from that
batch of material.
- Re-evaluate, increase the
frequency of quality
inspection of raw materials
to 2 months/time.

Frequency: Every day

OPRP-3 P: Sand, dust,
(P)
insect
fragments.

Verification

- What: Manage the operating
Finished product
Process:
capacity of the machine during the - Training the operator for inspection in each batch
proper control
process
- How: Monitor the capacity of the - Use the alternative process
tea leaf washing machine regularly - Re-wash
Product: After the product is
- Frequency: Once a day (at the
found to have a problem, it
beginning of the shift)
should be fixed immediately
- Who: The person who operates
to avoid affecting the next
this process
process.

B-001

What: Monitoring freezing time,
temperature, humidity, and
sanitation of equipment
How: Visual inspection for
operating machine. Control proper
time and temperature

B-002

19

Process:
- Stop the pre-chilling
process and adjust the
temperature, time exactly.
- Determine the cause of
microbial contamination

-Test the chiller using
standard daily
temperature, at the start
production, 4 hours/time
during operation per day.


- Humidity control is
extremely important

- Specific
sanitizing
procedure

Frequency: Periodical check and
clean chiller 3 months/time
Who: Process operator or
supervisor.

OPRP-5 B:
- Wash hands properly so as
(B)

- C. botulinum, not to contaminate the
E. coli,
product with
Salmonella from microorganisms
workers
- Mold

OPRP-6 B: - Bacillus
(B)
spp.,
Clostridium
spp.,
Staphylococcus
spp.
- Bacteria or
mold

- Personal What: Personal hygiene
hygiene
thoroughly and control packaging
before
conditions
participating - How: Evaluate worker hygiene
in the
and ensure appropriate
production environmental conditions for
- Store the package in a dry - Control products at the packaging stage
place and check the package the
- Frequency: Every day
regularly

temperature - Who: Factory workers who are
and
assigned in this process
humidity

- Controlled by GMP/GHP
- Clean and maintain the
machine regularly
- Place the product in a dry
place

-The
automatic
boxing
machine
must be
cleaned and
up to
standard
-The space
must be dry

during the pre-chilling
- Check and clean the
process and thoroughly
chiller 3 months/time
inspect the machinery
periodically by a mechanical
engineer.
Product:

- The product is destroyed
immediately and used for
other purposes.
Process
- Hygiene check of
- Isolate the entire product of workers before working
the frozen tea concentrate - Check temperature and
batch
humidity for the product
- Sampling product for
storage environment
testing to find out the cause
of spoilage
Product:
- Disposition of product
contaminated with
organisms or mold by
destroying or reusing it for
another purpose

- What: Equipment sanitation
Process:
Finished product
procedures to prevent cross- Stop the boxing process, inspection in each batch
contamination
determine the cause of mold
- How: The machine is cleaned
and bacterial contamination.
properly and make sure it is placed - Contact the cleaning
in a dry place

department. The cleaning
- Frequency: Twice a day (at the maintenance plan will be
beginning and the end of the shift) reviewed and changed if
-Who: Supervisor
necessary.
Product:
- Isolate products that show
signs of mold

20

B-003

Boxing
inspection
report


DISCUSSION AND CONCLUSION
1. Discussion:
The process to make instant green tea powder is divided into four stages: (1) material
receiving (paper box, tea leaves, water, and aluminum foil sachet), (2) handling tea
leaves (washing tea leaves, rolling/griding, drying), (3) instant green tea powder
processing (extraction, filtration, aroma stripping, concentration, pre-chilling, freezedrying), (4) packing and metal checking stage (packaging, sealing by heat sealer, metal
detector, and labeling).
For each step in the production of instant green tea powder, four hazards (biological,
physical, chemical, and allergen) need to be identified.
To determine whether the hazards are CCP or not, it is necessary to answer four
questions of the decision tree. Overall, there are three steps that are considered as CCP.
By answering five questions of decision tree, each hazard is determined to be an OPRP

or not. Generally, there are six steps that are considered as OPRP in processing.
Non-CCP hazards:
Several processing steps are not CCP because:
- Some of the steps can be controlled by checking the quality of the raw materials
before they are used (receiving water, tea leaves,...).
- Some steps are controlled by the good implementation of GMP, GHP, SSOP, so they
are CP.
- In some steps, they have been had measures related to the environment and a
combination of control measures to eliminate or reduce hazards to an acceptable limit
in the end product. Several steps like pre-chilling, packaging, boxing/labeling, etc. can
control temperature, periodically check equipment, and put it in the proper places in
the production line. In addition, some steps like water receiving, washing, tea leaves
receiving can also control the number of pesticides, toxic substances, so they are
OPRP.
- Few steps in production are eliminated or handled in subsequent steps (pathogenic
microorganisms can be controlled in step 13 (freeze-drying), sand, gravel can be
controlled in step 5 (washing), impurities of metal samples can be controlled in step
17 (metal detector).
- Several steps are controlled by AVL/COA.

21


CCP hazards:
• CCP-1 (B): It is a microbial hazard that may occur during the freeze-drying
step. The main microorganisms are L. monocytogene and Salmonella may still
survive in the frozen tea concentrate. The freeze-drying process is specially
designed with a temperature at -35oC in 8 hours which is far away from the
ideal conditions for the growth and development of these dangerous bacteria.
The cross-contamination from environmental factors such as the unclean

machine, the untreated processing space surrounding can lead to the welcome
of some pathogenic bacteria that can be harmful to the final product. Besides
that, the freeze-drying step is also the subsequence step to control other
bacterial hazards such as E. coli microorganisms, yeasts, and molds from the
filtration step, and L. monocytogene and Salmonella form pre-chilling step if
they may be not treated carefully. For this CCP, the corrective actions are
isolating the batch of frozen tea concentrate contaminated with
microorganisms; destroying or using the failed product for other purposes;
additionally, are determining the cause of this contamination during the freezedrying process, and retraining the line operators if necessary. To complete the
verification, microbiological testing must be done after each batch of the
products.
• CCP-2 (B): It is a microbial hazard during the sealing process. When the
product is not completely and properly sealed, green tea powder will easily
absorb moisture from the air because it has been freeze-dried, so it has high
hygroscopicity. Air humidity in Vietnam is relatively high, so if not controlled
properly, it will affect the nutritional content and quality of green tea powder.
When moisture is absorbed into the green tea powder, it creates conditions for
the growth of microorganisms in the green tea powder (especially mold). This
hazard can not be reduced or eliminated in subsequent steps, so it is considered
as CCP. The corrective actions are training the operator, stopping the sealing
process if the product is not completely sealed, isolating the product that is not
completely sealed and left out for too long. To verify it, the operation of the
machine and the humidity in the air must be checked before starting work, the
finished product of each batch must be inspected.
• CCP-3 (P): The last CCP is a physical hazard that may occur during the metal
detector step. The main physical hazard is metal fragments that still appear in
the product. Metal fragments may be detected in the instant green tea powder
by an electronic metal detector. However, if the electronic metal detector is not
properly calibrated, processing factors such as ambient humidity may create an
interference signal that may mask metal fragments. Metal fragments should

22


also be considered a significant hazard at the metal detector step. The hazard of
metal fragments may also be controlled by passing the product through the
metal detector to remove product packages containing metal. Metal fragments
can be removed from a green tea powder after they have been introduced by
passing it through a screen, magnet, or flotation tank. In addition, the metal
detector step is also the subsequence step to detect another physical such as
impurities of metal sample in instant green tea powder. In this step, it should
need to set critical limits that no metal fragments are detected in the product
that passes through the metal detector. Take the following corrective action if
the product is involved in a critical limit deviation that reworks to remove metal
fragments from any product rejected by the metal detector. To verify it, the
metal detector needs to be checked by using validated sensitivity standards
daily, every four hours during operation.
Non-OPRP hazards:
Part of the processing is not OPRP because:
- A few steps are PRP (paper box receiving, Aluminum foil sachet receiving, ...).
- Some other steps are CCP (freeze-drying, sealing by heat sealer, metal detector).
- Several steps have control measures that can be easily eliminated or handled hazards
during production such as cleaning, inspection, concentration control, monitoring,
maintenance, etc., so they are not OPRP.
OPRP hazards:
• OPRP-1 (C): It is a potential chemical hazard that can occur during the tea
leaves receiving step. Details that, after harvesting, trucks with specialized
boxes or trucks holding teabags transfer the tea leaves rapidly to the processing
plant. As a result, tea leaves can be polluted by the environment during the
transit process. Tea can also be influenced by chemical factors such as
inappropriate use of agrochemicals, sabotage, adulteration, residues of

pesticides and pesticides. This hazard control measure is raw material quality
check by the criteria of residues of pesticides which must meet the standards of
Circular 50/2016/TT-BYT (Vietnam). The corrective actions of this OPRP are
mentioned as follows if the criteria exceed the allowable limit, then stop
production, isolate the batch of materials, contact the supplier to return the
goods. Recall production from that batch of materials, then reassesses,
increasing the frequency of material quality checks to 2 months/time.
Besides, verification is also very necessary because, through this work, it is
possible to control the quality of raw materials received. They are checked
every 6 months and QC will be the manager and check the result sheet.

23


• OPRP-2 (C): It is a potential chemical hazard that can occur during the water
receiving step. In particular, pesticides, toxic substances can be mixed in the
water that is received. Thus, this hazard will be controlled by GMP and SSOP
by the way that takes a water sample before used for testing. The corrective
actions of this OPRP are listed as follows determining the cause of the
contaminated water; treating or disposing of the water source and changing to
a new water source if necessary. As for verification, firstly, making a diagram
of the water supply system. Secondly, controlling the operation of the system
to maintain good operation of the treatment system, protecting and preventing
the water source from the risk of contamination. Finally, checking water
quality: planning and taking test samples, handling problems when having
results.
• OPRP-3 (P): It is a potential physical hazard that can occur during the washing
step. Sand, dust, insect fragments are things that can be left in the water used to
wash the tea leaves. Hence, it is necessary to perform well GMP and SSOP,
clean and maintain the machine regularly. Besides, the operating capacity of

the machine during processing must meet the cleaning of leaves. The corrective
actions of this OPRP according to process that training operators for proper
control. After that, the alternative procedure is used. Next, tea leaves are
washed again. About products, after the product is detected a problem, it needs
to be fixed immediately to avoid affecting the next process. Finally, inspecting
finished products for each batch for verification.
• OPRP-4 (B): It is a microbial hazard that may occur during the pre-chilling
(freezing) step. The main microorganisms are L. monocytogenes, Salmonella
may still survive during pre-chilling. In this step, it is specially set up with a
temperature at -18oC in two hours which proper condition for inhibiting
microorganisms. However, if the temperature, the time is not adjusted correctly
and the equipment is not checked carefully, the microbiological hazard can
occur in this step. Thus, the pre-chilling process must be controlled the time
and temperature, there is a specific sanitizing process, especially the humidity
control is extremely important because this is a condition for the growth of
microorganisms. For this OPRP, the corrective actions are stopping the prechilling process and adjusting the temperature, time exactly, determining the
cause of microbial contamination during the pre-chilling process, and
thoroughly inspecting the machinery periodically by a mechanical engineer;
additionally, the product must be destroyed immediately or used for other
purposes. To verify it, we need to test the chiller at standard temperature daily,
checking and cleaning the chiller every month periodically.
24


• OPRP-5 (B): It is a microbial hazard during packaging. The main pathogenic
is the survival of C. botulinum, E. coli, Salmonella from workers, and mold
during packaging control of temperature, humidity, and personal hygiene
before entry into production to reduce the adverse effects of microbiological
hazards. The corrective actions include isolating the entire product of the frozen
tea concentrate batch, sampling product for testing; and disposition of product

contaminated with organisms or mold by destroying or reusing it for another
purpose. To verify this, we need to check worker hygiene, product storage
environment temperature, and humidity.
• OPRP-6 (B): The last OPRP is a microbial hazard during the boxing/labeling
process. The main pathogenic is the survival of spore-forming bacteria
(Bacillus spp., Clostridium spp., Staphylococcus spp.), and mold during
boxing/labeling. The boxing/labeling process is specially designed with dry
space; the automatic boxing machine is cleaned and up to standard. For this
OPRP, the corrective actions are stopping the boxing process, determining the
cause of mold and bacterial contamination; contacting the cleaning department
if necessary; additionally, discard products showing signs of mold. To complete
the verification, a finished product inspection in each batch must be done after
the boxing/labeling process.
2. Conclusion:
To have good and quality instant green tea powder products, besides a properly
designed manufacturing plant layout, a suitable product manufacturing process. The
products must meet the standards of HACCP, ISO 22000, as well as be assessed for
risk and identified hazards by the HACCP plan and OPRPs plan which focuses on
hazard identification, assessment, and control so that the hazards can be identified,
assessed, and then the appropriate corrective actions and control measures for these
hazards will be applied.

REFERENCES
Bourdoux, S., Rajkovic, A., De Sutter, S., Vermeulen, A., Spilimbergo, S., Zambon,
A., . . . Technologies, E. (2018). Inactivation of Salmonella, Listeria
monocytogenes and Escherichia coli O157: H7 inoculated on coriander by
freeze-drying and supercritical CO2 drying. 47, 180-186.
Sinija, V., Mishra, H., & Bal, S. J. J. o. F. E. (2007). Process technology for production
of soluble tea powder. 82(3), 276-283.
Huang, M., & Zhang, M. (2013). Tea and coffee powders. In Handbook of Food

Powders (pp. 513-531): Elsevier.
Park, J., Back, C., & Kim, J. (2005). Recommendation of packing method to delay the
quality decline of green tea powder stored at room temperature. Korean Journal
of Horticultural Science & Technology, 23(4), 499-506.
25