Good Hygiene Practices along the coffee chain Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5) Module 4.5

Slide 2 Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5) Objectives and contents  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

Slide 3 Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5) Why flow diagrams?  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

Slide 4 Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5) A good flow diagram  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

Slide 5 Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5) Constructing a flow diagram  Flow charts constructed on the basis of  Interviews  Observations  Blueprints or other documents  Model form provided

Slide 6 Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5) Evaluating process steps  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

Slide 7 Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5) Completing Form 3 – example of boia production Coffee cherryLabelled jute bagsOther ingredients 1. Harvesting2. Receiving 3. Transport4. Storing 5. Floatation separation ……… 25. Shipping Date:Approved By:

Slide 8 Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5) What is a plant schematic?  Diagrammatic representation of establishment showing  Product, ingredient flow  Employee movement patterns

Slide 9 Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5) Why a plant schematic?  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

Slide 10 Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5) Sample schematic – Plant for production of currants QC Control Outdoor storage Indoor storage Staff changing rooms Finance / extension office Co-operative shop Fumigation chambers Receipt of currants Processing lines Dispatch / supplies in Staff entrance Packaging Packaged product

Slide 11 Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5) On-site confirmation  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

Slide 12 Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5) On-site confirmation  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

Slide 13 Module 4.5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5) Summary  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