HACCP PlanPreserves

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Hazard Analysis Critical Control Point Plan for

La Dolce Vita Preserves, Algonquin College

Brenda Kubanowski

May 18, 2012

1

Table of Contents

Flowcharts ................................................................................................................................................... 2

Packing, Cooling and Storing (All Products) ....................................................................................... 3

Strawberry Jam ..................................................................................................................................... 4

Apricot Jam ........................................................................................................................................... 5

Brown Sugar Apple Sauce .................................................................................................................... 6

Smoked Ketchup ................................................................................................................................... 7

Caramel Sauce ...................................................................................................................................... 8

Chai Sugar............................................................................................................................................. 9

Vanilla Sugar ...................................................................................................................................... 10

Orange/Cranberry Marmalade ............................................................................................................ 11

Duck Fat .............................................................................................................................................. 12

Recipes with Critical Control Points ....................................................................................................... 13

Steam Cabinet - Packing, Cooling and Storing Procedures for All Recipes ...................................... 14

Tilt Fryer - Packing, Cooling and Storing Procedures for All Recipes .............................................. 15

Strawberry Jam ................................................................................................................................... 16

Apricot Jam ......................................................................................................................................... 17

Brown Sugar Apple Sauce .................................................................................................................. 18

Smoked Ketchup ................................................................................................................................. 19

Caramel Sauce .................................................................................................................................... 20

Chai Sugar........................................................................................................................................... 21

Vanilla Sugar ...................................................................................................................................... 22

Orange/Cranberry Marmalade ............................................................................................................ 23

Duck Fat .............................................................................................................................................. 24

Monitoring and Record Keeping ............................................................................................................. 25

Preparation of Jars, Lids and Utensils Checklist................................................................................. 26

Production Procedures Checklist ........................................................................................................ 27

2

Flowcharts

3

Packing, Cooling and Storing Flowchart

(All Products)

Preparing Equipment

Steam Cabinet or Tilt Fryer

Packing

Sealing

Steam Cabinet or Tilt Fryer

Labelling

Storing

CCP - Place clean and sanitized jars, new lids,

funnel and jugs in steam cabinet for at least 10

minutes.

CCP - Put on a new pair of latex gloves and remove jars and equipment.

CCP - Ladle hot product into jars leaving at least 1 cm headspace.

Place lids on jars and screw on until fingertip tight.

CCP – Ensure that lids have sealed (depressed) and discard any jars that have not sealed.

CCP - Label with product name, company name, best before date (see individual recipes and

flowcharts), ingredient list, nutrition information, storage instructions (see below) and (except

for flavoured sugars) instructions for refrigeration after opening.

CCP - Cool upright, undisturbed for 24 hours. Store at 21°C in a dark place with a relative

humidity of 50-60%.

CCP - Return to steam cabinet for at least 5

minutes.

CCP - Return to tilt fryer for at

least 10 minutes.

Critical Control Point (CCP) - Turn on

steam cabinet and set to 10 PSI.

CCP - Fill tilt fryer with water to 60 litre

mark and set to 205°C (400°F). Wait for

water to come to 100°C.

CCP - Place clean and sanitized jars, new

lids, funnel and jugs in tilt fryer for at least

20 minutes.

4

Strawberry Jam Flowchart

Lemons IQF Strawberries or Fresh Strawberries Sugar

Storing

Preparing

Cooking

Packing, Cooling and Storing

Receiving

Store in

refrigerator.

Store in

freezer.

Store in dry

storage.

Rinse lemons. Defrost

strawberries in

colander over

drip pan in

refrigerator 2

days in advance.

Discard

juice.

Put in tall saucepot and lightly mash.

Bring to full rolling boil (100°C) and continue boiling for 10 minutes only.

CCP – Without cooling product, follow HACCP procedures for packing, cooling and storing.

Include instructions to use within six months from date of production, refrigerate after opening

and use within 7 days.

Juice and

discard

seeds and

rind.

Store in

refrigerator.

Rinse and

remove leaves.

5

Apricot Jam Flowchart

Lemons Dried Apricots White Sugar

Storing

Preparing

Cooking


Receiving

Store in

refrigerator.

Store in dry

storage.

Store in dry

storage.

Rinse lemons.

Soak dried

apricots in water

and lemon juice

for 12-18 hours

before use under

refrigeration.

Discard water and mince in buffalo

chopper.

Add to stainless steel pot with 2 L of water.

Simmer for 90 minutes. Do not overcook.




Juice and

discard

seeds and

rind.

Warm sugar over low heat.

6

Brown Sugar Apple Sauce Flowchart

Lemons Apples Apple Cider Vanilla Cinnamon Nutmeg Brown Sugar White Sugar

Storing

Preparing

Cooking


Receiving

Store in

refrigerator.

Store in dry storage.

Rinse

and

core

apples.

Simmer for 25 minutes.




Pass through food mill using large die/sieve. Add vanilla, cinnamon, nutmeg, lemon juice,

white and brown sugars to apple purée.

Rinse

lemons;

juice and

discard

seeds and

rind.

Put apple cider and

cored apples into a

stainless steel pot.

Simmer for 40 minutes only.

7

Smoked Ketchup Flowchart

Onions Garlic Tomatoes Olive Oil Canned Tomatoes Cider Vinegar Brown Sugar Rice Wine Vinegar Molasses

Storing

Preparing

Cooking


Receiving

Store in

refrigerator.


Smoke with wood for 30 minutes.




In stainless steel pot, add smoked tomatoes, garlic and onions. Then add olive oil, canned

tomatoes, brown sugar, cider vinegar, rice wine vinegar and molasses.

Rinse, peel and chop tomatoes, garlic and onions.

Heat slowly and cook for 120 minutes.

8

Caramel Sauce Flowchart

Pasteurized Unsalted Butter Pasteurized 35% Cream White Sugar

Storing

Cooking


Receiving

Store in refrigerator. Store in dry storage.

In stainless steel pot, add sugar and heat slowly to caramelize.




Slowly add cream and stir carefully for 20 minutes.

Strain and add cold butter.

9

Chai Sugar Flowchart

Cinnamon Green Cardamom Pod Cloves Ground Ginger Vanilla Bean White Sugar

Storing

Preparing


Receiving


In Robocoupe, add

sugar and blend

until it is a fine

powder (10x, like

fruit sugar); empty

and put aside.

CCP – Follow HACCP procedures for packing, cooling and storing. Include instructions to

use within six months from date of production.

In Robocoupe, add whole cinnamon, green cardamom pod, cloves, ground ginger, vanilla

bean; add sugar and blend for 10 minutes.

10

Vanilla Sugar Flowchart

Vanilla Bean White Sugar

Storing

Preparing


Receiving


In Robocoupe, add sugar and blend

until it is a fine powder (10x, like

fruit sugar).

CCP – Follow HACCP procedures for packing, cooling and storing. Include instructions to

use within six months from date of production.

Add vanilla bean and blend for 10 minutes.

11

Orange/Cranberry Marmalade Flowchart

Lemons Oranges Dried Cranberries Ground Cloves White Sugar

Storing

Preparing

Cooking


Receiving


Rinse, slice

and seed

oranges and

lemons.

Soak dried

cranberries in

water for 12-18

hours before use

under

refrigeration;

drain and discard

water.

Simmer sliced oranges

and lemons for 2 hours in

stainless steel pot; strain

and cool.




Warm sugar over low heat.

Add warmed sugar, oranges, lemons, cranberries, cloves and 2 liters of water to stainless

steel pot; simmer for 90 minutes.

12

Duck Fat Flowchart

Duck Fat Garlic Nutmeg Dried Sage

Storing

Preparing

Cooking


Receiving


Peel, rinse and

chop garlic.

Melt duck

fat.




Add garlic, nutmeg and sage.

Heat until garlic starts to turn colour (roast); let warm for 2 hours.

Strain.

13

Recipes with Critical Control Points

14

Steam Cabinet - Packing, Cooling and Storing Procedures for All

Recipes

PREPARING EQUIPMENT

CCP 1. Turn on steam cabinet and set to 10 PSI.

CCP 2. Place clean and sanitized jars, new lids, funnel and jugs in steam cabinet for at

least 10 minutes.

PACKING

CCP 3. Put on a new pair of latex gloves and remove jars and equipment.

CCP 4. Ladle hot product into jars leaving at least 1 cm headspace.

5. Place lids on jars and screw on until fingertip tight.

SEALING

CCP 6. Return to steam cabinet for at least 5 minutes.

CCP 7. Ensure that lids have sealed (depressed) and discard any jars that have not

sealed.

LABELLING

CCP 8. Label with product name, company name, best before date (see individual recipes

and flow charts), ingredient list, nutrition information, storage instructions (see below) and

(except for flavoured sugars) instructions for refrigeration after opening.

STORING

CCP 9. Cool upright, undisturbed for 24 hours. Store at 21°C in a dark place at 50-60%

relative humidity.

SANITATION INSTRUCTIONS: Ensure all equipment has been calibrated. Wash hands

before handling food, after handling raw foods and after any interruption that may contaminate

hands. Wear new gloves for packing procedures. Use only new lids. Wash, rinse and sanitize

equipment and utensils before and after use.

15

Tilt Fryer - Packing, Cooling and Storing Procedures for All

Recipes

PREPARING EQUIPMENT

CCP 1. Fill tilt fryer with water to 60 litre mark and set to 205°C (400°F). Wait for

water to come to 100°C.

CCP 2. Place clean and sanitized jars, new lids, funnel and jugs in tilt fryer for at least 20

minutes.

PACKING

CCP 3. Put on a new pair of latex gloves and remove jars and equipment.

CCP 4. Ladle hot product into jars leaving at least 1 cm headspace.

5. Place lids on jars and screw on until fingertip tight.

SEALING

CCP 6. Return to tilt fryer for at least 10 minutes.

CCP 7. Ensure that lids have sealed (depressed) and discard any jars that have not

sealed.

LABELLING

CCP 8. Label with product name, company name, best before date (see individual recipes

and flow charts), ingredient list, nutrition information, storage instructions (see below) and

(except for flavoured sugars) instructions for refrigeration after opening.

STORING

CCP 9. Cool upright, undisturbed for 24 hours. Store at 21°C in a dark place at 50-60%

relative humidity.

SANITATION INSTRUCTIONS: Ensure all equipment has been calibrated. Wash hands

before handling food, after handling raw foods and after any interruption that may contaminate

hands. Wear new gloves for packing procedures. Use new lids only. Wash, rinse and sanitize

equipment and utensils before and after use.

16

Strawberry Jam

Ingredients Weights and Measures

Strawberries 2 kg

Sugar 1 kg

Lemon juice 35 ml

PREPARING

1. Defrost IQF strawberries two days in advance in colander with drip pan and discard

liquid or rinse and remove leaves from fresh strawberries.

2. Lightly crush strawberries and combine with lemon juice and sugar in a tall stainless

steel pot.

COOKING

3. Stir over low heat until sugar is dissolved.

4. Increase to high heat and bring to full rolling boil; continue to boil for 10

minutes.

PACKING, COOLING AND STORING

CCP 5. Without cooling product, follow HACCP procedures for packing, cooling and

storing. Include instructions to use within six months from date of production,

refrigerate after opening and use within 7 days.

SANITATION INSTRUCTIONS: Wash hands before handling food, after handling raw foods

and after any interruption that may contaminate hands. Wear new gloves for packing

procedures. Wash, rinse and sanitize equipment and utensils before and after use. Return all

ingredients to refrigerated storage if preparation is interrupted.

17

Apricot Jam


Dried apricots 0.5 kg

Sugar 0.75 kg

Lemons 1

Water 2 L

PREPARING

1. Soak dried apricots in water and lemon juice for 12-18 hours before use under

refrigeration. Discard water and mince in buffalo chopper.

2. Rinse lemons. Juice and discard seeds and rind.

COOKING

3. Warm sugar over low heat in stainless steel pot. Add apricots, lemons and water.

4. Simmer for 90 minutes. Do not overcook.









18

Brown Sugar Apple Sauce


Granny Smith apples 10

Apple cider 1 L

Vanilla extract 0.03 L

Cinnamon 0.05 kg

Nutmeg 0.03 kg

Lemon juice 0.05 L

Brown sugar 0.5 kg

White sugar 0.3 kg

PREPARING

1. If using fresh lemons, rinse lemons; juice and discard seeds and rind.

2. Rinse and core apples.

COOKING

3. Put apple cider and cored apples into a stainless steel pot and simmer for

25 minutes.

4. Pass through food mill using the large die/sieve.

5. To the apple puree add, vanilla, cinnamon, nutmeg, lemon juice, white and brown

sugar and simmer for 40 minutes only.









19

Smoked Ketchup


Onions 0.1 kg

Olive oil 0.1 L

Canned Tomatoes 2.84 L

Garlic 0.05 kg

Tomatoes 0.5 kg

Brown sugar 0.4 kg

Cider vinegar 0.2 L

Rice wine vinegar 0.1 L

Molasses 0.09 L

PREPARING

1. Rinse, peel and chop tomatoes, garlic and onions.

COOKING

2. Smoke with wood for 30 minutes.

3. In stainless steel pot, add smoked tomatoes, garlic and onions. Then add olive oil,

canned tomatoes, brown sugar, cider vinegar, rice wine vinegar and molasses.

4. Heat slowly and cook for 120 minutes.









20

Caramel Sauce


Pasteurized Unsalted Butter 0.454 kg

White Sugar 1 kg

Pasteurized 35% Cream 1 L

COOKING

1. In stainless steel pot, add sugar and heat slowly to caramelize.

2. Slowly add cream and stir carefully for 20 minutes.

3. Strain and add cold butter.









21

Chai Sugar


White Sugar 0.2 kg

Cinnamon 0.01 kg

Green cardamom pod 0.005 kg

Cloves 0.005 kg

Ground ginger 0.005 kg

Vanilla bean 1

PREPARING

1. In Robocoupe, add sugar and blend until it is a fine powder (10x, like fruit sugar);

empty and put aside.

2. In Robocoupe, add whole cinnamon, green cardamom pod, cloves, ground ginger,

vanilla bean; add sugar and blend for 10 minutes.



storing. Include instructions to use within six months from date of production.





22

Vanilla Sugar


White Sugar 0.1 kg

Vanilla bean 1/8th

PREPARING

1. In Robocoupe, add sugar and blend until it is a fine powder (10x, like fruit sugar);

empty and put aside.

2. Add vanilla bean and blend for 10 minutes.



storing. Include instructions to use within six months from date of production.





23

Orange/Cranberry Marmalade


Dried cranberries 0.4 kg

White Sugar 1.625 kg

Lemons 4

Ground cloves 0.005 kg

Oranges 10

Water 2 L

PREPARING

1. Soak dried cranberries in water for 12-18 hours before use under refrigeration; drain

and discard water.

2. Rinse, slice and seed oranges and lemons.

COOKING

3. Simmer sliced oranges and lemons for 2 hours in stainless steel pot; strain and cool.

4. Warm sugar over low heat.

5. Add warmed sugar, oranges, lemons, cranberries, cloves and 2 liters of water to

stainless steel pot; simmer for 90 minutes.









24

Duck Fat


Duck fat 0.2 kg

Nutmeg 0.005 kg

Garlic 0.02 kg

Dried sage 0.01 kg

PREPARING

1. Peel, rinse and chop garlic.

COOKING

2. Melt duck fat.

3. Add garlic, nutmeg and sage.

4. Heat until garlic starts to turn colour (roast); let warm for 2 hours.

5. Strain.









25

Monitoring and Record-Keeping

26

Preparation of Jars, Lids and Utensils Checklist

Steam Cabinet Tilt Fryer

Date Name Signature Set to 10 PSI Equipment

processed

at least

10 minutes.

Filled to 60

liter mark

with water

and set to

205°C

(400°F).

Wait for

water to

come to

100°C.

Equipment

processed

at least

10 minutes.

27

Production Procedures Checklist

Date Product

Name

Prepared

by

pH Critical Limit

Exceeded?

(note limit that has

been exceeded

and corrective action

taken)

Tilt

Fryer

Processing

Time

Steam

Cabinet

Processing

Time

Seal

Checked?

Labelled

with date

and product

name?

Signature

HACCP PlanPreserves

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