FOODCORP:SUNBAKE RUSTENBURG

EXPERIENTIAL LEARNING PRESENTATION

Name of Student: Richard Stephens SebolaStudent Number: 211226072

Name of Supervisor: Mohlapa Mogowe

Job title: Food Safety Technician

Job description: Food safety technician is responsible for making sure that the bread manufactured at the facility is safe and will not harm consumers when prepared for its intended use by implementing and maintaining Good Manufacturing Practices, Prerequisite programmes (PRPs), and providing training to staff.

INTRODUCTION

A food safety technician must conduct HACCP analysis and check the quality of the bread.

At Sunbake Rustenburg we manufacture three types of products namely sliced and unsliced 700g Brown bread,700g White bread, and sliced 700g Crushed wheat bread.

INTRODUCTION Cont.....

PROCESS FLOW DIAGRAMRaw material receiving

Premix

Mixing

Divider

Rounder

Intermediate Proofer (First proofing)

Moulder

Second proofer (Final proofing)

Oven Baking

Deppaning

Cooling

Bagging and Slicing

Packaging

Despatch

THE PRODUCTION PROCESS

Premix and mixing – all the ingredients, except flour, water, and yeast are weighed and added together at premix and the premix is then mixed with flour, water, and yeast during mixing.

Divider and rounder: The dough is then divided into dough units and then these units are rounded into circle by the rounder machine.

Intermediate proofer: The dough is then rested for about 5 minutes, this way the dough will not be sticky and rubbery and it will easily go through the moulder rollers without tearing.

Proofing and baking: After the dough is moulded and panned, it enters the proofer where the cell structure will form stable networks and then the bread is baked at required temperature to kill microorganisms which can harm consumers

Deppaning and cooling: After baking the bread is lifted from then pans by suction cups onto the conveyor to the cooler where the bread is cooled to a required Temperature.

Slicing and Packaging: After the cooler the bread is then sliced and then packaged.

Despatch: The bread goes to despatch and then distributed to the market.

PRODUCTION PROCESS Cont…

PRODUCTION PROCESS Cont…

Figure 1: Divider Figure 2: Spiral Mixer

Table 1.1 DutiesROUTINE Microbial sample collection Receiving and filing check

sheets

Daily Chlorine Checks Daily Analysis: Bread quality and retention

Distribution of food safety check sheets.

Dispatch Bread Checks Ambient temperature recording.

AD HOC DUTIES

Process Control and locker inspection.

ADMINISTRATIVE Preparation of audits (External)

Verification of Scales and Thermometer

Photocopying Auditing pre-requisite programs (PRP’s)

GMP audits, Personal hygiene checks & Approves jewellery

Recording of trends and GMP findings on the system

Shelf life testing

Weekly glass and brittle plastic monitoring

Sending of Microbial samples

DUTIES

Analytical testing Surface swabs: Swabs were taken from different machine and

equipment (Scales) parts which come in contact with product and sent for Total Microbial Activity (TMA) testing.

Raw Material: Each month a different raw material was tested. Raw materials are tested for microorganisms as per suppliers specifications to check if what is on the COA complies.

Monthly testing finished product: Every month bread (brown, white or crushed wheat) was sent for normal microbial testing. TMA, Coliforms, Escherichia coli, yeast and mold, Staphylococcus aureus and Salmonella were tested.

Materials and Methods

Analytical testing cont.., Hand Swabs: Swabs were taken from production workers by rubbing off the

inside of hands and between fingers and equipment by rubbing on the equipment then send for E. coli and Staphylococcus aureus

Air analysis: The petridish containing agar was exposed to the air which is in contact with product ,then it was sent to the laboratory for TMA and Yeast and Mold.

Shelf-life testing: The bread was put inside a box and then sent to the lab for TMA, Coliform and E.coli Yeast and Mold, Salmonella and Staphylococcus aureus

Water: Water sample were collected from the tap using sterile sampling bottles ordered from Laboratories for faecal coliform, Coliform, E. coli and TMA testing.

Materials and Methods

Production Premix: Ingredients are weight as per accepted specifications using

calibrated scales Mixing: All ingredients are mixed in the Spiral mixer Divider: After mixing, the dough is divided into several units and

weighed Rounder: Dough is rounded into spherical and smooth shape Intermediate proofer: The rounded dough is rested in the proofer Moulder: The dough is then moulded and cut into four pieces. Proofer: Dough is proofed to pan height at a set temperature and a

humidity Oven: Bread is baked at a temperature of 210-280 ̊C for a period of

20.7 minutes Cooler: Bread is cooled before bagging and slicing

Materials and Method Cont…

Quality control, Quality assurance and Stock control Quality Assurance: Ensuring that all equipments like oven, metal

detector and scales are set on the correct parameters as per specifications and are all working properly.

Quality Control: The bread was weighed to make sure it meets specification (Trade and Metrology Act of 1973), under weight, over baked and collapsed bread were rejected. Texture, slice width, shape of the bread, and taste were also checked.

Stock Control: Stock Control: Flour was delivered every Friday for the next week. All other raw materials were ordered at a certain minimum level. All baked bread was counted using a bread counter. After packaging, stock is counted before being dispatched. Ensure that enough stock is available at food safety department for taking samples for micro testing.

METHOD AND MATERIALS Cont…

METHOD AND MATERIALS Cont…We must make sure that our product meet customer expectation

Figure 3: QA & QC Overview

Figure 4: Metal Detector

External/Internal Audits Good Manufacturing Practices audits are conducted by Food Safety

Technician with the help of Food Safety Controller weekly. Internal bakery Audits done by Food Safety Managers from other

Sunbake bakeries PRP’s audits are conducted once In two months by the food safety

team. DQS (ISO 2200:2005) audit once a year . Pick n’ Pay (Intertek/FSA) audit once a year . SANS 10049

requirements prerequisite programs (PRPs), ISO/TS 22002 PRPs on food safety, Hazard Analysis Critical Control Point (HACCP), Food Safety Management System requirement as guided by the Global Food Safety Initiative (GFSI) and applicable laws, regulations and compulsory specifications.

MATERIALS AND METHOD Cont…

Ad hoc projects

Pre-requisite programs by evaluation and checking different departments (areas) for cleanliness, waste disposal, usage of energy, water and air as well as pests control. The aim is to verify the programs effectiveness

Preparing for external audits by making sure all the documents are in place and available when needed by the auditor and accompanying the auditor through the plant.

Shelf life testing: Bread shelf life tested yearly to verify if the bread actually lasts the five days we declare on the packaging.

MATERIALS AND METHODS Cont…

Conducting of internal audits was very important for me during this six months, GMP audits and PRPs as we have to make sure we give our customers/consumers the best quality products.

Process control: It is important to control the process from start to finish, as there can be deviations in between.

Food Safety Monthly Meetings: It is important to report to management all the activities that involve food safety so that they know what is going on.

EXPERIENCE GAINED

THANK YOU