INTRODUCTION
1.1 Background
AAA FOOD ENTERPRIZES is a small scale factory started way back in 1990.
It deals in producing squash from both fruits and juice-imitation flavors.
1.1.2 Location
It’s located in Kampala. It is an in-home cottage factory.
1.1.3 Ownership
It is a private enterprise owned by Mrs.AAA since 1990. It is registered
as an “enterprise” under the laws governing registration of companies in
Uganda.
1.1.4 Why it was started
The initial objective was to raise income for the owner that would help
her cater her family. After fulfilling the above objective successfully, the
proprietor now has another objective of growing it to a medium-scale and later
large scale juice processing factory that can achieve many ends including
providing employment to the youth.
1.1.5 Products
The enterprise deals in drinks of two types;
1. “Partly natural” squashes of pineapple, mango, passion fruit and Oranges.
These are branded as “AAA”.
2. Purely artificial imitation drinks of different flavors namely; pineapple,
mango, passion fruit, oranges, straw berry and black currant. These products
are branded as “DDD”.
1.1.6 Organization Structure of the enterprise
The company is currently fully managed and run by one person, the
proprietor, with the rest being ordinary workers. She takes all the key
decisions and guides all the operations and proceedings of the business. She
currently employs three kinds of employees, the production workers (3), a
marketer (1) and a shop keeper of the outlet in Kampala town (1).
1.1.7 Challenges faced
The proprietor had faced several problems with this business including;
1. Spoilage of the squash especially partially natural pineapple and
passion fruit based squashes.
2. Lack of proper onsite technical guidance about her operations.
3. Theft of money especially by the marketers that she usually charged
with duties of marketing the products, delivering them to customers (squash)
and collecting the money after sales have been made.
1.1.8 Objectives of the internship
The major objectives ware;
1. To provide technical guidance on processing, quality control and
quality assurance.
2. To find a solution to the spoilage of squash.
The minor objectives were to;
1. To identify the cause of spoilage (swelling of the plastic bottles).
2. To devise means of solving the problem.
3. To establish and strengthen the enterprise’s quality control and
quality assurance system.
2.0 METHODOLOGY
In order to identify the problems, the intern used observation and
verbal interaction to get to know the details of the processing operations. The
section includes detailed information about the processes and facilities at AAA
enterprises.
2.1 Raw materials, procurement and Delivery
The raw materials used include;
a) Fruits namely passion fruit, Oranges, Pineapples and Mangoes. These
are used to make the AAA brand type of squashes.
b) Imitation flavors and food colors. These are used to make the DDD brand
and to enhance the flavor and color of natural fruit based squashes.
c) Portable water that is purified using a water purifier which employs
U.V light and a carbon filter. The purifier removes microbes, suspended organic
matter and sterilizes the water. It is this purified water that is used in
mixing the squashes since cold filling is done.
2.2 Delivery and storage
On delivery, the fruits are washed and prepared for pulping. In case
they are not worked upon, they are stored in the enclosure till the next day.
However this is rare. Pulping is done using a fabricated pulper made of
stainless steel. It’s used for oranges, passion fruit and pineapples.
2.3 Raw material Treatment
There is little control on the quality of raw materials. They are bought
from Owino market from middle men who purchase them from farmers in the growing
areas. Quality control is only controlled after purchase. They do sort out all
the damaged and injured fruits, and use the rest. The fruits are washed 3
consecutive times, cut into halves (peeled and sliced for pineapples) and then
pulped. The pulp is preserved by boiling (pasteurization) and application of
chemical preservation (sodium benzoate at levels of 0.02%). It is then hot
filled into plastic containers that are tightly filled after. This pulp can
last for over 4 months according to the proprietor.
Note: From the pulp, a portion is
always drawn off and used in production of AAA brand as and when required. The
Period of use ranges from one to four months.
In the above processes;
-Normally 100 liter batches are mixed and the above steps are followed.
However the following are to note.
1. The natural fruit is pasteurized at about 60o C, a
temperature inadequate to kill pathogenic microorganisms and significantly
reduce the microbial load.
2. Preservatives are weighed, mixed with hot water and placed into the
mixing drum.0.05% benzoate and 0.02% potassium sorbate is used.
3. Using a wooden spoon, the mix is stirred to dissolve the ingredients
and thoroughly distribute them. This can easily introduce microbes into the
juice as it’s not disinfected even between batches being mixed.
4. Packaging is treated as follows.
a). Bottles are Rinsed in a batch of water. This water is only changed
after realizing it’s dirty (on changing color). The bottles are now placed in
the same bag they occupied before and then carried to the processing room. They
are laid besides a basin in which filling is done.
b). Covers are washed and left soaked in water (that is often not clean)
from where they are screwed onto the bottles.
2.5
Facilities and Design
2.5.1
Machines
·
Fabricated Blender. This is made of stainless steel and used to mix CMC
and hot water. The mixture
is stored and used for 2-3 days.
· Fabricated fruit pulper for
mangoes, passion fruit and pineapples. This is electrically powered and used to
generate fruit pulp from fruits. Prior to use, it is washed with hot water to
disinfect it.
· A fabricated
boiler/kettle/batch pasteurizer (not in use due to high electric power
requirements). This has a mixer and a tap to release the contents into the
filling bucket.
· A sensitive weighing scale
powered by a battery to accurately weigh preservatives.
2.5.2
Storage facilities
· A cupboard used to store
preservatives and other additives that are not currently in use.
·
Raw material
store for;
-Plastic
bottles and Box cartons
-fruit concentrate, approximately 10x10 feet.
2.5.3 Processing facilities and equipment
There is a processing room that is approximately 10X13feet. This holds
all the processing equipment and utensils, and the personnel engaged in
processing. With exception of pasteurization, all other processing operations
take place in this room. Pasteurization is done in the kitchen that is just
near to the processing room. This has a local well built stove using wood fuel.
A glass thermometer (max. 110oC) is used for controlling
pasteurization temperatures. Other facilities in the processing room include;
Filter-cloths that are pink/ green/ blue colored; Plastic drums, basins,
buckets, jugs and other containers for use during mixing and filling; a large
heavy gauge polythene sheets that is laid down on the ground during packing
among others.
2.5.4 Water supply and treatment
There is a supply of piped portable water from National water and
Sewerage Cooperation. The water is purified using water purifier that uses a
carbon filter and U.V light to purify and disinfect water.
2.5.5 Dressing material
The enterprise equips its workers with white over coats, head gears and
mouth pieces.
2.5.6 Toilet
This is found besides the processing room and in a good state of
hygiene. It clean and provisions for soap and water for washing hands exist on
the door way. The area out side this acts as the change room.
3.0 RESULTS AND DISCUSSION
3.1 PROCESS FAULTS AND CORRECTION MEASURES
The
faults realized about the design and process operations are summarized in the
table below together with the corrections that can be made.
4 4.0 CONCLUSIONS AND
RECOMMENDATIONS
4.1 CONCLUSIONS
With the above observations, I conclude that this enterprise can be
helped by;
1.
Shifting from the current situation to the
desired situation as indicated in the observations’ section above.
2.
Educating them about Good Manufacturing
processes especially hygiene and sanitation aspects, to ensure that they
appreciate them, commit to and adhere to them.
3.
Drawing up a HACCP plan for the processes
they under take that is relevant to their area and condition of work (Appendix
1&2).
4.
Coming up with standard operating procedures
for their process operations and Hygiene and Sanitation (Appendix 3).
5.
Obtaining equipment and materials that can
allow them meet basic hygienic conditions and sanitation standards, as
elaborated in the table below.
APPENDIX 1
Suggested requirements for AAA FOOD ENTERPRIZES required for it to make
its processes controllable and hygienic.
|
Item
|
Source
|
Estimated cost per unit
| ||
|
White gum boots
| ||||
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White aprons
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White gloves
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White muslin cloths
| ||||
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Sensitive weighing scale
| ||||
|
Digital Refractometer
| ||||
|
Digital thermometer
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Digital Ph meter
| ||||
|
Filling / mixing tank with a tap
| ||||
|
Stainless steel table or other food grade
| ||||
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Other items to fix
| ||||
|
Ceilliing in the processing room
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|
Smoothen the floor, if possible with Tarrazo
| ||||
AAA ENTERPRIZES HACCP PLAN FOR PRODUCTION OF JUICE
AAA (CONCETRATE)
