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

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

2. 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)

3. 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)

4. 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)

5. 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)

6. 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)

7. Completing Form 3 –example of boia production Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram(Tasks 4 & 5)

8. 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)

9. 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)

10. 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)

11. 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)

12. 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)

13. 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)