 DRAFTING OF THE HACCP

PLAN FOR ROASTED AND

GROUND COFFEE FOR THE
COMPANY “SPECIAL
COFFEES”




 “NATIONAL UNIVERSITY
OF THE ALTIPLANO”
 FACULTY OF
AGRICULTURAL
SCIENCES
 EP AGROINDUSTRIAL
ENGINEERING
PRESENTED BY:
 Maribel Sacaca Villalba
 Rocio Nelida Tumbillo Livise
 Nancy Gloria Hurtado Rodrigo
ROASTED AND GROUND COFFEE FROM THE COMPANY “SPECIAL
COFFEES”

I. INTRODUCTION
The general objective of this work is to develop and implement a HACCP
plan (Hazard Analysis and Critical Control Points) for roasted and ground
coffee from the “specialty coffees” company, as a proposal for improvement
and thus be able to correct the control of the process. of its elaboration.

The evaluation and diagnosis of the company “specialty coffees” was carried
out using tools learned in classes where a HACCP team was formed and a
task was assigned to each one, the product description was carried out, and a
product flow diagram was prepared. , HACCP team meetings
(brainstorming), and the application of the seven principles of the HACCP
system.

II. AIM
II.1. General objective
 Prepare and implement a HACCP plan (Hazard Analysis and Critical
Control Points) for roasted and ground coffee from the “specialty
coffees” company.
II.2. Specific goal
 Evaluate the microbiological, chemical and physical hazards in the
roasted coffee production process.

III. HACCP TEAM COMPOSITION

III.1. HACCP TEAM MEMBERS AND ORGANIZATION CHART

The HACCP team is integrated as follows:

Coordinator: MARIBEL SACACA VILLALBA

Production specialist: EUGENIO FLORES TAZA

Technical specialist: ROCIO NELIDA TUMBILLO LIVISE

Secretary: NANCY GLORIA HURTADO RODRIGO

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 Figure 1. HACCP team organization chart

III.2. FUNCTIONS
III.2.1. Coordinator:

 Schedule, lead meetings.

 Suggest changes.
 Coordinate teamwork.
 The coordinator must be familiar with HACCP.
 Ensure team decisions are communicated.
 Delegate responsibilities to the HACCP team.
 Conduct internal audits
 Attend to the reunions
 Periodically supervise the areas involved in the production process,
as well as verify the system documentation.

III.2.2. Production specialist:

 Have knowledge of the process of making roasted coffee.

 Management of field work and production machinery
 Organize and schedule daily production
 Verify compliance with process parameters.
 Evaluate raw material and input requirements
 Attend meetings scheduled by the HACCP team
 Verify that the product to be shipped is in good storage conditions.

III.2.3. Technical specialist:

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  Have knowledge in the evaluation of microbiological, chemical and
physical hazards.
 You must know how to configure the environment and the
development tool selected for the project.
 You must know the characteristics or parameters of the database
selected for the project if necessary.
 Verifies compliance with the cleaning and sanitation plan in such a
way as to ensure the health of all equipment and its environment.
 Record the control of critical points in the production process

III.2.4. Secretary:
 Organize meetings and record HACCP team meetings
 Write down the minutes of the meetings and the work table.
 Have a record of the decisions made.
 Attends HACCP team meetings.

IV. PRODUCT DESCRIPTION

PRODUCT NAME ground roasted coffee

BRAND “Specialty coffees”

Product obtained from the roasting of
parchment coffee and its subsequent grinding.
The color has a medium degree that allows it to
ensure good fine acidity on the palate, denoting
DESCRIPTION an attractive and lasting taste. It has an intense
aroma of coffee accentuated in the preparation,
soft and delicate bitterness.

PRESENTATION Packaging of 250 gram trilaminated bags.

Store in a cool, dry place with adequate
STORAGE AND
ventilation and not exposed to sunlight in its
CONSERVATION METHOD
respective closed container.
It has a maximum shelf life of 1 year under
established storage conditions, with a

3
 consumption recommendation within 6 months.
USEFUL LIFE

V. FLOWCHART DESIGN

V.1. MACHINERY (DESCRIPTION)

MACHINERY OF THE COMPANY “SPECIAL COFFEES”
JR-15Kg Coffee Roaster
 Digital Temperature Reader that is located inside the Roasting chamber in
direct contact with the grain, to have a real and precise temperature.
 Grain viewer, Sample collector witness,
 Automated motion cooling paddles,
 316L stainless steel cooler,
 Ignition through an automatic spark gap
 Turning on the roasting chamber through a selector
 Cyclone and cooling tray through a selector.
 Analog Clock, for Air flow
 Pressure gauge for gas control (PSI)
 Solenoid (For gas safety system)
 Materials: 316L Stainless Steel, bronze and carbon steel, volcanic rock.
JR 5QQ/hour Polishing Pilling Machine
 Piller with Bohler steel treatment blades.
 grain exit temperature of 35 to 40 ºC,
 Container for collecting independent husk, container for receiving grains
stacked on a tray.
 2.5m pneumatic elevator
 7.5HP motor
JR-80 Coffee Grinder A 100Kg/h
 Concentric stainless steel discs in martensitic material with heat treatment.
 3HP Motor (Three Phase)
 Mill regulation system from the finest to the coarsest (11 Regulations).
 316L stainless steel hopper
 Chap. 6kg hopper
Balance Zaranda
Unit 1 Unit 1

4
Brand: WEIGHT Capacity: 10Kg/hour
Capacity:30KG Brand: JR

V.2. MAP OF THE ROASTED AND GROUND COFFEE PRODUCTION

PLANT

5
V.3. FLOW CHART FOR THE PROCESS OF MAKING ROASTED AND
GROUND COFFEE

6
 Trite

V.3.1. Process description

.
 Reception: Reception is carried out in jute bags by the supplier and the
parchment coffee is subsequently weighed in the same bagged bags. The
weighing is carried out on a WEIGHT brand scale with a capacity of 30
kg.
 Selection: This process allows us to eliminate all coffee beans that have
defects such as stains, scratches, small perforations or deformities, as
well as to select the beans by size (sieve classification).
 Threshing: The raw material enters the threshers without damaging the
grains. Threshing is the husking or peeling of the grain cover, removing
the silvery shells by polishing.
 Roasting: The brown beans are roasted in the “MEDIUM ROAST”
roaster, at 220°C for 11 minutes. It is in this process that the chemical

7
 change is generated that fully develops each and every one of the aromas
in the coffee.
 Ground: The grinding process will be carried out by using the coffee
mill. This grinding stage will be a key operation in the chain of making a
good coffee. The ground grain must have a granulometry perceptible to
the touch and not reach a floury consistency.
 Packaging: The parchment coffee, already ground, is packaged in
trilaminated PET/VMPET/LDPE bags, to preserve the aroma and essence
of the coffee.
 Storage: After completing the packaging process, the product will be
stored in a specific area of the same premises, at a temperature of 23°C
and a humidity of 69% with ventilation.

VI. PREPARATION OF THE HACCP PLAN

VI.1. HAZARD IDENTIFICATION

Process Identification of critical points

Chemical Pesticide (DISULFOTON)

Reception Physical Stones, hair, straw, dust.

Biological Molds, escherichia coli, salmonella,

ochratoxin A
Chemical x

Selection Physical Stones, hair, straws, dust

Biological Mold

Chemical equipment maintenance lubricants

(mobile semi-solids)
Trite Physical Bohler steel metals

Biological x
Chemical Caffeine
Toasted
Physical x

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 Biological x

Chemical x
Ground
Physical Staff accessories

Biological Spores

Chemical Humidity control

Packing
Physical Staff accessories

Biological Escherichia coli

Chemical Temperature and humidity control.

Storage
Physical Dust
Biological Moisture mold

9
VI.2. ASSESSMENT
STAGE DANGERS CAUSES PRECAUTIONARY MEASURES
Reception Chemical Pesticide Some suppliers deliver parchment Request documents from the supplier that
(DISULFOTON) coffee without a certificate certify the absence of pesticides.
Physical Stones, hair, straw, Lack of control at the time of Make an exhaustive selection of screens.
dust. receipt of raw materials
Biological Molds, escherichia Bad reception Ask the supplier to have good hygiene and
coli, salmonella, care practices in the drying process.
ochratoxin A
Chemical x x x
Selection Physical Stones, hair, straw, Bad reception Make a comprehensive selection
dust.
Biological Molds, escherichia Bad reception Upon receipt, ask the supplier for a
coli, salmonella, certificate of good practices.
ochratoxin A
Chemical equipment Chemical contamination due to change of equipment (thresher)
maintenance traces of oil/maintenance lubricant
Trite lubricants
(mobile semi-
solids)
Physical Metals Physical contamination by foreign change of equipment (thresher
bohler steel bodies (pieces of the equipment
itself)
Biological x
Chemical Increased caffeine Reevaluate roasting time and temperature
range control
Caffeine
Toasted Physical x

1
 Biological microbiological x x
Chemical cross poor plant layout redistribute the coffee processing plant
contamination
Ground (staff perfume)
Physical Staff accessories poor manufacturing practices implement good manufacturing practices
earrings, rings.
Biological Spores Contamination of the work practice good hygiene practices
environment, due to lack of
hygiene.
Chemical Humidity control Lack of product humidity control Measure the control parameters of the
product and the environment before
Packing packaging.
Physical staff accessories, Contamination due to bad practices Good manufacturing practices by
packaging with by staff, inefficient equipment personnel, change equipment (sealing
basic sealer (sealing machine). machine).
Biological x
Chemical Cleaning products Poor hygiene practices, poor carry out good hygiene practices, properly
(chlorine, duck storage location. distribute the plant
Storage detergent)
Physical Dust poor plant layout properly distribute the plant
Biological insect Due to the presence of sugars in the pest control
contamination (ant) composition of coffee.

2
VI.3. HACCP SYSTEM DECISION TREE

1
TABLE PREPARED ACCORDING TO THE DECISION TREE TO DETERMINE
THE CCPs

PROCESS DANGER P1 P2 P3 P4 PCC

Chemical Pesticide Y YE - YE IT IS NOT

(DISULFOTON) E A AH A CCP
A H
H
RECEPTION
Physical Stones, hair, Y YE - YE IT IS NOT
straw, dust. E A AH A CCP
A H
H

Biologica Molds, YE IT IS NOT

l escherichia coli, AH A CCP
salmonella, Y YE -
ochratoxin A E A
A H
H

physical Stones, hair, Y YE - YE NOT A

straw, dust. E A AH CCP
A H
H
SELECTION
biologica Molds, Y YE - YE IT IS NOT
l escherichia coli, E A AH A CCP
salmonella, A H
ochratoxin A H
Chemical equipment
maintenance
lubricants Y YE - YE NOT A
TRITE (mobile semi- E A AH CCP
solids) A H
H
Metals
Physical bohler steel Y YE - YE NOT A
E A AH CCP
A H
H
Chemical Caffeine Y YE YE NO IF IT IS A

1
 TOASTED E A AH PCC
A H
H
Chemical cross Y N YE YE IT IS NOT
contamination E O AH AH A CCP
GROUND (staff perfume) A
H

Physical Staff accessories Y N YE YE IT IS NOT

Earrings, rings. E O AH AH A CCP
A
H
Biologica Spores Y N YE YE IT IS NOT
l E O AH AH A CCP
A
H
Chemical product humidity Y YE YE NO IF IT IS A
PACKING control E A AH PCC
A H
H
Physical staff accessories, Y N NO - NOT A
packaging with E O CCP
basic sealer A
H
STORED Chemical Cleaning Y N NO - NOT A
products E O CCP
(chlorine, duck A
detergent) H
Physical Dust Y N YE YE IT IS NOT
E O AH AH A CCP
A
H
Biologica insect Y N YE YE NOT A
l contamination E O AH AH CCP
(ants) A
H

VI.4. ADOPTION OF CONTROL MEASURES AND SPECIFICATIONS

(critical limits)

CONTROL
PROCESS DANGE PCC MINIM MAXIM CONTROL

2
 R UM UM MEASURES
TOASTED CHEMIC CAFFEIN 10 11 TIME
AL E minutes minutes CONTROL
210°C 220°C TEMPERATUR
E CONTROL
PACKING CHEMIC HUMIDIT 2% 3% HUMIDITY
AL Y 15°C 16°C TEMPERATUR
E

VI.5. MONITORING:

HACCP PLAN
Roasting coffee process
“SPECIAL COFFEES”
TOASTED COFFEE Temperature and toasting time control

ROAST T° CORRECTIVE
TIME OBSERVATIONS V°B°
NO. (Temperature) ACTIONS

3
 ____________________ _____________________
V°B° HEAD OF QUALITY CONTROL V°B° PRODUCTION
HEAD

HACCP PLAN
Roasting coffee process
“SPECIAL COFFEES”
TOASTED COFFEE Humidity control in packaging

CORRECTIVE
humidity temperature OBSERVATIONS V°B°
ACTIONS

4
____________________________ _________________________
V°B° HEAD OF QUALITY CONTROL V°B° PRODUCTION
HEAD

VI.6. CORRECTIVE ACTIONS:

PROCESS DANGER CONTROL CORRECTIVE

ACTIONS
TOASTED Caffeine T° and time 1.- identify the entire
product involved in
the deviation.

2.-Isolate the affected

product with a
marking label for its
next use.

3.-allocate it to other
production lines, such
as the production of
energizers.

PACKING Humidity Humidity and 1.- Identify the entire

Temperature product involved in
the deviation.
2.- isolate the affected

5
 product with a
marking label for its
next use.

3.- determine their

consumption by
shortening the useful
life time to 3 days.

Annexes:

TECHNICAL SHEET OF PARCHMENT COFFEE

PRODUCT NAME Coffee (coffea arabica)

TRADENAME Coffee bean, parchment coffee.

Humidity: 12% °H.

Smell: clean and fresh.
PHYSICAL DESCRIPTION OF Color: even and uniform.
THE PRODUCT Grain size: mesh number 15

Peru, Puno Department, Sandia Province, San Pedro

ORIGIN de Putina Punco district, “Munay Pata” farm

From coffee seeds, the final industrialization of

parchment coffee is roasted, ground, caffeinated,
FORMS OF CONSUMPTION decaffeinated, mixed with sugar or as soluble coffee.
It can also be used as an input in industry.

COMMERCIAL Packaging: jute bags.

CHARACTERISTICS OF THE Storage: 18-25°C, 60-75%RH
PRODUCT Odor: characteristic free of strange odors foreign to

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 the product, Certified by USDA ORGANIC.
State of development: well-developed parchment
coffee bean without deformations, no flat beans and
maximum humidity of 12% Organic coffees.
SHELF LIFE OF PARCHMENT Up to 06 months, stored in proper conditions.
COFFEE
The province of Sandia where approximately six
AREA IN PRODUCTION
thousand hectares of coffee are cultivated.
PRODUCTION DATES March- October

JR MACHINERY TECHNICAL SHEET

PRO FORMA

Sirs):

SUBJECT: technical sheet of Coffee Machinery

DATE: February 3, 2017

Receive a cordial greeting, I am pleased to address you to present our pro forma Coffee
Machinery.

PRODUCT DESCRIPTION PRICE

JR-15Kg Coffee Roaster

 Digital Temperature Reader that is located inside the Roasting

chamber in direct contact with the grain, to have a real and precise
temperature.
 Grain viewer, Sample collector witness,
 Automated motion cooling paddles,
 316L stainless steel cooler,
 Ignition through an automatic spark gap
 Turning on the roasting chamber through a selector
 Cyclone and cooling tray through a selector.
 Analog Clock, for Air flow
 Pressure gauge for gas control (PSI)
 Solenoid (For gas safety system)
 Materials: 316L Stainless Steel, bronze and carbon steel, volcanic
rock.

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 2.5m pneumatic lift

JR 5QQ/hour Polishing Pilling Machine

 Piller with Bohler steel treatment blades.

 grain exit temperature of 35 to 40 ºC,
 Container for collecting independent husk, container for receiving
grains stacked on a tray.
 2.5m pneumatic elevator
 7.5HP motor

Tubular size sorter with 5 outlets (1 clean and 4 selections) JR

5QQ/hour

 1.5HP reducer motor with variable speed drive

 1 Stainless steel cleaning roller.

JR-80 Coffee Grinder A 100Kg/h

 Concentric stainless steel discs in martensitic material with heat

treatment.
 3HP Motor (Three Phase)
 Mill regulation system from the finest to the coarsest (11
Regulations).
 316L stainless steel hopper
 Chap. 6kg hopper

Trilaminated JR bag sealer, with temperature regulation and

With regulation for bag capacity, seals all types of bags.

Electronic Panel

QUOTE VALIDITY: 20 days

Delivery Time: 60 calendar days

PAYMENT METHOD: 70% upon signing the contract and 30% upon delivery of the
machine and training.

SAVINGS ACCOUNT NO.:

 CTA SAVINGS BCP: 410-21655027-0-57

 NATIONAL BANK: 04475100080

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 ROMAN VELASQUEZ HURTADO
GENERAL MANAGER

Image n° 1: with the production specialist, making agreements for good dialogue in the
haccp preparation process.