HACCP

Some useful links for Commercial HACCP form & Decision Tree

1. http://www.cfsan.fda.gov/~acrobat/haccp4x1.pdf (Hazard analysis worksheet)
2. http://www.idfa.org/reg/dectree.pdf (How to make decide a CCP)
3. http://www.fao.org/docrep/W8088E/w8088e06.htm (Blank HACCP form)
4. http://www.oznet.ksu.edu/meatscience/forms/flow.doc (Blank sheet of flow chart)
5. http://www.oznet.ksu.edu/meatscience/forms/Hazard%20Analysis%20Table.doc (Hazard Analysis)

*Number is not in the order of importance

Pastry making!

Pastry Making (Hand Make)

Hello! Correct me if I am wrong k. :) we are going to send our curry puffs oversea rite? Which means our “frozen curry puff” is not fried yet? It is still “raw”. So we are only making the pastry (Skin of the curry puff) & cooking the fillings?

Ingredients for making pastry (skin of Curry puff)

Plain flour
Melted margarine
Water mixed with ½ teaspoon of salt

1. In a large bowl, combine flour and margarine.

2. Add in water a little at a time and knead until dough becomes smooth and pliable.

3. Leave it for 10 - 15 minutes then, with a rolling pin, roll out the dough into a thin sheet (0.5cm).

4. Using a round cookie cutter, cut the dough into circles and place a little filling in the middle.

Ingredients for curry puffs fillings

These veggies can be added in steps 5a. & hard boiled eggs can be include 5c?

Potatoes (cubed, boiled and drained)
Cubed chicken flesh
**Mixed Vegetables (Carrots, Peas, Beans, Corn)
** Hard boiled eggs
Mince onion
Curry powder
Coconut milk or milk
Butter
Salt to taste

5a. For the filling, heat a pan and sauté the onions in the butter until soft.

5b. Add in chicken and curry powder and fry until fragrant.

5c. Finally, add in potatoes, milk, seasonings and cook until thick.

6. Fold over and pleat the ends of the pastry to seal in the filling.

Additional steps (Agar agar one):
Ø Cool the curry puff for a short period of time as the fillings are still warm
Ø Freeze to -20 degree via blast freezing in 30 minutes
Ø In a “form-fill-seal” machine, pack 10 pieces of curry puffs into a “plastic bag” (Those commercially used)
Ø Pack 10 bags into each carton box
Ø Store in freezer & transport? (-20 degree)

7. Deep fry curry puffs until golden. (Not needed as we are packing as “raw” frozen curry puffs oversea)


“Some” links:
http://www.winkler-global.com/News.html
http://www.alibaba.com/catalog/10869172/Frozen_Curry_Puff_Samosa_Meat_Chicken_.html
http://www.martins-seafresh.co.uk/frozen_facts.htm

Product Recall

Product Recall...

What is it ALL about?

What is a Product Recall?

A food recall includes any corrective action by a company needed to protect consumers from potentially adverse effects of a contaminated, adulterated, or misbranded product.

A recall is a voluntary action, and the recall decision is made by the company management. If the company does not initiate a recall, the government agency responsible for the particular product category may request that the company do so. Recalls are conducted by industry in cooperation with federal and state agencies.

Manufacturers strive to prevent a recall. Employing Good Manufacturing Practices (GMP) and Hazard Analysis Critical Control Points (HACCP) plans are vital to preventing a recall.

Factors prompting a food recall include but are not limited to unsafe, contaminated, or mislabeled product, nonconformities to manufacturer?s specifications, and missing allergen or other hazard warnings.

Purpose of a Recall

The basis of the recall concept depends on a company's food safety policies, ethical understanding, regulatory requirements, and financial constraints.

A recall protects not only the consumer, but also the company. A smooth recall process can save a company's name and prevent further damage due to negative publicity. Destroying, replacing, or altering the product are the three main corrective actions. A recall plan should strive to achieve the following goals:

A. Protect consumer health
B. Comply with existing rules and regulations
C. Minimize the cost of the recall
D. Regain and improve the company?s reputation

************************************************************************************

Aims of a recall

The aims of a product recall should be to minimise the risk of injury to the public by recalling the product as quickly as possible to get back as many of the faulty products as possible
to minimise the cost and inconvenience for the consumer and the company.

Assessing the need for a recall

When you become aware of a possible defect in a product that may make it unsafe you will need to consider a recall. To decide if a recall is necessary

1. Gather all available information on the defect. Arrange testing, talk to buyers/customers who have complained

2. Identify the number of goods affected (models, batches)

3. locate the goods - where they have been distributed (warehouses, retailers, customers)

4. Assess the degree of danger – injury potential and likelihood of injury

5. Consult others who may have received complaints or who can offer advice on the need for a recall.

Product defects

The fault in a product could be:

With the product itself

eg, a manufacturing fault causes a weld on a bicycle to fail and the bicycle collapses while it is being ridden.

Failure to meet a mandatory standard

eg, a product safety standard made under the Fair Trading Act, an electrical safety standard cited under electrical safety legislation, or a vehicle standard set out in the Transport Regulations.

With the packaging

eg, a cap on a bottle of household cleaner that does not fit properly.

Caused by the use made of a product

eg, the fuel line in a motor vehicle fractures under extreme temperature and road conditions.

Carrying out the recall

Once a problem in a product has been identified a recall should be carried out quickly and efficiently.

This checklist will help you to organise a recall:

1. Nominate one person to coordinate the recall.
2. Stop production and distribution of the product.
3. Identify which models/ batches of the product are affected (eg by serial numbers, batch marking). Find out when these were produced and where they have been distributed.
4. Notify distributors, wholesalers, importers, agents and retailers quickly and in writing.
If the hazard is particularly serious notice should be given by fax or telephone, followed by a letter (see "Content of Publicity").
5. Notify relevant government departments that you are undertaking a recall

6. Make arrangements for providing refunds, replacing or repairing the recalled product.
7. Notify individual customers directly of the recall where records are available.
8. Prepare and undertake a publicity programme to ensure all users of the product are aware of the recall.
9. Arrange to destroy the faulty products or to store them securely until they can be made safe.
10. Keep a record of items returned. Record who returned the goods and the date. Keep a count of how many items are still outstanding.
11. Evaluate the success of the recall using the record of returns. If the recall has not achieved a satisfactory rate of return you will need to develop new strategies for publicising the recall.
12. Analyse the record to see which groups of buyers or which regions have a low return rate and choose suitable methods to inform these groups of the recall.

Notifying relevant agencies

***********************************************************************************

Type of publicity

Recalls are usually publicised through direct contact with customers, or through newspaper advertising.

However, there are other ways you can publicise a recall. You need to consider which is most likely to get the message to the people who are using the product concerned.

Some groups in the population are not regular newspaper readers, others will read some papers but not others, eg community newspapers but not daily newspapers. Think about who you are trying to reach.

Here are some of the possible means of publicising a recall:

1. Display signs in shops that sold the product
2. Dsk relevant organisations to publicise the recall in their newsletters, eg Nestle might publicise the recall of a Nestle Chocolate
3. Avertise in magazines in which the product was advertised
4. Advertise in daily or community newspapers
5. Issue a media release to newspapers, radio and television
6. Advertise on radio or television
7. Advertise in retailers' mailers. Supermarkets, retail chains, department stores often send mailers to every household.

You need to decide which combination of methods will reach the most users of the product.

Content of publicity

Any publicity for the recall needs to include the following information:

1. A clear description of the product including the name, make, model, colour, batch or serial numbers
2. A clear drawing or photograph of the product
3. The dates that the product was available for sale
4. A statement of the problem and the associated risk
5. Immediate action to take - eg, cease use, safe storage instructions
6. What action consumers should take in order to receive a refund or to have the product repaired or replaced
7. A contact telephone number for further information, preferably a toll free number.


Here is an e.g. of a recall notice that could appear in a newspaper, mailer, shop sign, etc:

*************************

SAFETY WARNING

Recall of Bikerlite Bicycles

Two Wheels NZ Limited wishes to alert its customers that a batch of faulty bicycles has been sold throughout New Zealand from March of this year. The bicycles concerned are the Bikerlite 313 with Batch A27 stamped on the front forks. Some bicycles in this batch have a faulty weld on the handlebar stem which may cause the handlebars to fall off during normal use. If you have one of these bicycles please return it to any stockist of Bikerlite bicycles.
You will receive a full refund of the purchase price or a free repair. Do not use the bicycle in the meantime.

For further information about this recall please call
0800 000 000 TWO WHEELS NZ Ltd, Private Bag 000, Auckland

*********The End***********

Recipe for Package 1 (Chicky Curry Puffs)

Curry Puff Recipe

[Ingredients]

Pastry
Plain flour
Melted margarine
Water mixed with ½ teaspoon of salt

Filling
Potatoes (cubed, boiled and drained)
Cubed chicken flesh
**Mixed Vegetables (Carrots, Peas, Beans, Corn)
** Hard boiled eggs
Mince onion
Curry powder
Coconut milk or milk
Butter
Salt to taste

** Words in purple colour is sort of "Standard Recipe", the yellow wordings are what we can add to achieve the 7 Criteria!

The Processes

There are 2 methods to make curry puffs!

Method 1 is baking (Flaky curry puff :Healthier Method)
Method 2 is deep frying (Similar to Old Chang Kee)

Method 1

Assuming the pastry sheets are in the box.

1. Remove as many pastry sheets from the box as needed. Wrap the unused sheets in plastic wrap or foil and return them to the freezer.

2. Thaw the pastry sheets at room temperature for about 30 minutes.

3. Meanwhile, prepare the curry by frying mixed vegetables, potato pieces and spices in oil.

4. Unfold each pastry sheet on a flat surface such as a lightly floured board or countertop.

5. Expand the sheets carefully either with a rolling pin or with your hands.

6. Apply butter on both sides of the sheet.

7. Cut each pastry sheet with a knife or pizza cutter into 9 square pieces. You can first cut along the folded edges of the sheet to divide it into 3 parts and then cut 3 squares in each part ending up with 9 square pieces.

8a. Grease the aluminium foil with butter to avoid sticking.
8b. Place the squares on a large baking sheet or aluminium foil apart to allow for the pastry to puff up.

9. Fill each pastry with a spoon of curry in the middle, leaving room for sealing easily.

10. Seal filled pastries by folding the edges to form either a triangle or rectangle and pressing the edges together.

11. Preheat the oven to 176 Degree Celsius.

12. Bake the pastries in the preheated oven. About halfway through, check progress by peeking through the oven window or opening the door.

13. Bake the pastries in the oven for about 15 minutes or until the pastry puffs up and turns golden brown.

14. Turn over the pastries and bake for another 15 minutes or until the pastry puffs up and turns golden brown.


Method 2

1. In a large bowl, combine flour and margarine.

2. Add in water a little at a time and knead until dough becomes smooth and pliable.

3. Leave it for 10 - 15 minutes then, with a rolling pin, roll out the dough into a thin sheet (0.5cm).

4. Using a round cookie cutter, cut the dough into circles and place a little filling in the middle.

5a. For the filling, heat a pan and sauté the onions in the butter until soft.
5b. Add in chicken and curry powder and fry until fragrant.
5c. Finally, add in potatoes, milk, seasonings and cook until thick.

6. Fold over and pleat the ends of the pastry to seal in the filling.

7. Deep fry curry puffs until golden.

Instructions
Making of the fillings

1. Heat some oil in a wok and fry the potatoes.
2. Remove the potatoes and the oil from the wok.
3. Place another few tbsp of oil into the wok and fry the chicken meat with the onions, carrots and green peas. (Mixed Veggies)
4. Add the potatoes back into the wok and add in the rest of the seasonings (salt, curry powder, light soya sauce).
5. Stir fry the mixture until cooked, then leave it aside.

Pastry sheet layer

1. Mix the flour and oil together and form a dough.
2. Cut into equal pieces (Each piece must be big enough to be rolled out/flatten to about 1/2 cm thick and 13 cm dia. pastry sheet).

3. Mix all the ingredients together to form a dough and cut into equal pieces (Same as above).

Process for wrapping the fillings

1. Take 1 piece of the outer skin dough and roll into a ball.
Leave it aside.

2. Take 1 piece of the inner skin dough and roll into a ball.
Dough the 2 circular pastry balls together.

3. Flatten pastry with a rolling pin on lightly floured board to about 1/2 cm thick sheet.

4. Cut out round pieces about 12-13 cm in diameters from the flatten pastry.

5. Place a portion of the fillings& the egg onto the centre of the flatten pastry. (Fillings should cover about 10 cm dia.) Note: not to put too much fillings, or else it will be difficult to fold the pastry later on.

6. Fold the flatten pastry to forms a half circle such that it covers the fillings.

7. Press lightly to seal the edges.
Flute the edge by pinching and twisting the edge with your fingers. (Action: Pleating of the edges)

Cooking Method

Deep fry the puffs until golden brown.

Opps... Forgotten to ad in the Recipe for Curry powder!!!

Ingredients

1 teaspoon black peppercorns

1 teaspoon mustard seeds

1/2 teaspoon coriander seeds

1/2 teaspoon cumin seeds

1/2 teaspoon fennel seeds

1/2 teaspoon cayenne pepper

1 large bay leaf, broken

8 whole cloves

6-12 cardamom seeds (pods removed)

Method

In a spice-mill or blender, grind all the ingredients together until fine.

*If not using right away, store in an airtight container in the refrigerator.

An article on Food Safety

Food Safety Article

Definition of Food Safety:

Food safety refers to the conditions and practices that preserve the quality of food to prevent contamination and food borne illnesses.

What is Safe Food?

Safe food is food that is free from physical, chemical or microbial contaminants that may cause us harm. The present of microorganism has the highest food safety burden to consumers.
Food that has not been prepared safely may contain bacteria like E. coli. Unsafe food can also spread food-borne illnesses like Salmonellosis and Campylobacter infection. However, food-borne illness can be reduced by buying, preparing, and storing food safely.

Why Food Safety Matters?

Food can be contaminated in many different ways. Some food products may already contain bacteria or parasites. The germs can be spread during the packaging process if the food products are not handled properly. Failure to cook or store the food properly can cause further contamination.

Therefore, proper handling and preparation of food greatly reduces the risks of getting food borne illnesses.
Proper food preparations are necessary to prevent your family from becoming sick from food-borne illnesses caused by bacteria such as E. coli, Salmonella, Campylobacter and Listeria which may cause symptoms such as diarrhea, fever, abdominal cramps, nausea, vomiting, and dehydration. Food safety precautions include knowing how to select foods in the grocery store, how to store them, how to cook them, and how to clean up afterward.

In conclusion, Food safety is all about assuring that the food which reaches the table is fit for consumption. The risks of contamination are minimized, so that the population as a whole is healthier from the benefits of safe quality food.

How to keep food safe for consumption? [4C & 1S]

Clean: Wash hands and surfaces often.
Cook: Cook to proper temperatures.
Chill: Refrigerate promptly.
Check :Temperature of food
Separate: Do not cross-contaminate.

*Keep Food out of Danger Zone: 5-60 Degree for more than 4 hours. If possible, heat/warm up your food whenever possible!

Some guidelines of handling food safely

The best way to practice food safety remains to be well informed about the basic principles of food production and safe food handling at home.

1. Always wash hands with warm water and soap for 20 seconds before and after handling food.

2. Don't cross-contaminate. Keep raw meat, poultry, fish, and their juices away from other food (Cooked Food). After cutting raw meats, wash cutting board, utensils, and countertops with hot, soapy water.

3. Cutting boards, utensils, and countertops can be sanitized by using a solution of 1 tablespoon of unscented, liquid chlorine bleach in 1 gallon of water.

4. Marinate meat and poultry in a covered dish in the refrigerator.

5. Using a food thermometer is the only sure way of knowing if your food has reached a high enough temperature to destroy foodborne bacteria.

2 useful links to know more about Food Safety

10 reasons to keep food safe for consumption

http://www.fsis.usda.gov/Fact_Sheets/Top_Ten_Reasons/index.asp

All about Food Safety

http://www.foodlink.org.uk/factfile_c.asp?file=4&chapter=1

Food Safety Land

Welcome to Food Safety Land! :)