Malaysian Agricultural Research and Development Institute
GOOD MANUFACTURING PRACTICES
IN POSTHARVEST AND
MINIMAL PROCESSING OF
FRUITS AND VEGETABLES
Dr. Mohd. Salleh Punan
Malaysian Agricultural Research and Development
Institute (MARDI)
Training Course on Product Quality and Safety Management for Fruits and Vegetables, 17 November 2008
Content
• Introduction
• Control of packinghouse
• Control of raw materials
• Control of operation
• Control of finished-product
• Traceability
• Conclusion
Introduction
Why post harvest?
• Liberalization of international trade
• Domestic and export markets more
competitive
• Increase demand and production
• Quality and safety awareness
Quality
Level where product
or services satisfied
consumer’s demand
Subjective &
difficult to
quantify
objectively
Good Manufacturing Practices
Consistently and reliably delivering
products and services that have
been predetermined by the markets
Total quality management from
production until marketing levels
GMP Fruits and Vegetables
To control variability in:
growing techniques
seasonal effects
postharvest conditions
processing techniques
facilities
human factors
market conditions
Management of product, process,
people and services to customer
To overcome quality deterioration
Product
Service Process
People
GAP Requirements (Post harvest)
ELEMENTS SALM EUREPGAP
HARVESTING Hygiene Hygiene
Farm packing Farm packing
POST Treatment Treatment
HARVEST Washing Washing
GMP to Support GAP
• Develop and implement GMP
• Incorporating GAP, HACCP
• Use of national and international
standards
GMP Components
Control of packinghouse
Control of raw materials
Control of operation
Control of finished-product
Traceability
CONTROL OF PACKINGHOUSE
Packinghouse
Premises or covered
area where most of the
preparation and minimal
processing activities
shall be carried out
Location of Packinghouse
Packinghouse shall be located away
from sources of contamination
including environmentally polluted area
and area subject to flooding or prone to
infestations of pests or where wastes
cannot be removed effectively
Packinghouse located on farm or in
collection/wholesale/distribution centre
shall be in a segregated area
Premises Design
The premises should be designed
in such a way that the raw products
from farm enter at one end and the
finished products emerge at the
other end
Unfinished and finished products
should be kept separately and
never come into contact with each
other so as to avoid cross-
contamination
Layout Design
PRODUCE
FROM
FARM TEMPORARY
STORAGE RIPENING PACKAGING
ROOM ROOM MATERIAL
STORE’
MINIMAL
PROCESSING
COLD
ROOM
(0-5 oC)
TRIMMING/
EXTERNAL
CUTTING
S
STORAGE OF
FINISHED-PRODUCT
(2-5 oC)
WASHING
FRESH PRODUCE PREPARATION AREA
RIPENED
FRUITS
FOR MP
Minimal Processing Layout Plan
Plant hygiene and cleanliness
The premises should be well screened with
barriers designed to exclude vermin, domestic
and wild animals, birds and insects
Pest control and monitoring should be in place
Walls, floors and ceilings should be in good
condition and easy to clean and sanitize
Comprehensive cleaning and sanitation
programs should be implemented in the
premise, with more emphasis in the minimal
processing, packing and storage areas
Trash and waste material should be placed in a
specific area segregated from the processing
and storage areas, and be removed regularly
Facilities
Water supply
An adequate supply of potable water with
appropriate facilities for its storage,
distribution and temperature control shall
be available
Potable water shall be used for processing
of minimally processed products and
washing of food contact surfaces and
equipments
Facilities
Equipment and Instruments
Equipment and utensils used in MP
shall be of appropriate design
Those surfaces/parts that come into
contact with food shall be made of
non-toxic, smooth and non-porous
materials that can be easily cleaned
and sanitized e.g. stainless steel
Sanitary Operation
Facilities, equipment, machines
and instruments shall be cleaned
and maintained regularly
Surface of equipment in contact
with food shall be cleaned and
sanitized before and after each
batch operation
All chemical agents such as fuels,
additives, fertilizers, pesticides,
sanitizers, etc. should be
properly labeled and kept
separately from food products
and packaging material
CONTROL OF RAW MATERIALS
Raw materials received
• Produce
specification
from farm
• Raw material
inspection
Produce specification from farm
Type of produce and variety
Name/code of supplier, farmer, farm
Cultural practices
P&D controls
Maturity and ripening stage
Size & grade of produce
Quality, appearance, shape, sweetness, etc.
Pesticide and fungicide residual limits
Product temperature
Packaging and transportation methods
Quantity of supply
Raw Material Quality Standards
Prepared for produce specification from
farm
Base on National Standards (Malaysian
Standards), Regional Standard (ASEAN
Standards) or International Standards
(CODEX Standards)
Use specification agreed by both buyer
and seller
Raw Material Inspection
Inspection system conducted
consistently
Use instruments such as balance,
thermometer and caliper
Use Raw Material Specification as
reference
Use Quality Form as in Table 1
Decision to accept or reject
consignment based on the inspection
Table 1. Form for quality inspection of raw materials
RAW MATERIAL INSPECTION
SUPPLIER’S INFORMATION
Name of Supplier:________________________Date:____________Time:_________
Type of Produce:________________________Quantity:_______________________
Vehicle Reg. No.:_____________________ Produce Temperature:______________
Condition of produce while on the vehicle (packaging, label, arrangement):
______________________________________________________________________
______________________________________________________________________
INSPECTION
No. of container Net Damage Reject Accept
Weight Weight % Weight % Weight %
1
.
.
10
ACTION: 1. Consignment accepted
2. Consignment rejected Reason:____________________________
3. Consignment accepted with condition:_______________________
For option 2 and 3, return to:
Supplier: YES/NO Buyer: YES/NO Packinghouse Manager: YES/NO
Inspector’s Signature:________________Supervisor’s Signature:_______________
CONTROL OF OPERATION
Harvesting &
In-field Handling
60-65 days after anthesis
40-45 days after bagging
Packinghouse operation
• Produce packed according
to the market’s
specification
• Monitoring process and
products microbiological,
chemical or physical
hazards (HACCP)
Finished-product Specification
Type of Produce and Variety
Packer’s Name/Code
Size and Grade of Produce
Quantity, appearance, shape,
sweetness, etc.
Packaging and Labelling
Storage & Shelf life
Tolerance to damage
P&D and Quarantine practices
Flow of Packing Operation
Receiving
Sorting
Trimming
Washing
P&D Treatments
Drying
Grading
Packaging
Minimal Processing
Produce peel/cut into ready-to-eat portion
Ease in serving portion of large & difficult to
peel fruit
Reduce packaging and transportation costs
More convenience
Maintain freshness
Monitoring process and products
microbiological, chemical or physical
hazards (HACCP)
Minimal Processing Unit Operation
Receiving
Ripening
Washing
Minimal Processing
Packaging
Storage
CONTROL OF FINISHED-PRODUCT
Table 2. Form for inspection of finished-product
FINISHED-PRODUCT INSPECTION
Product:_______________________ Packinghouse:_________________________
Code:________________________ Date of Inspection:_______________________
Sampel No.:_______________________Time of Sampling:_____________________
1. Presentation and label:
Suitability of box/container
Cleanliness, accepted/not
Information labeled/enough/not
Class/grade written/not
Date of packing
Code of Supplier/Packer
Posthatvest practice
2. Weight/Quantity of product:
Gross weight
Net weight
3. Product Quality:
Total/% comply specification
Total/% damage due to:
* outside size/weight range
* physical /mechanical
* rotten/disease
* maturity/ripening
* temperature
* appearance/shape
* others
4. Follow-up handling:
Storage/transport temperature
Arrangement/palletization
ACTION:
Product comply all specification: YES/NO
Action taken if not comply specification:__________________________________
Product shelf life could be maintained: YES/NO
Inspector’s Signature:________________Supervisor’s Signature:_______________
Name:_____________________________ Name:_____________________________
Cold Chain
Maintain cold chain system
Monitor storage and
transport temperature
Scheduled quality analysis
of stored produce
Transportation
• Domestic
• Regional
• Long distance
Air shipment
Emphasis on suitable
packaging,
maintenance of cold
chain before and after
distribution
Sea shipment
Refrigeration
Market Display
TRACEABILITY
Record & Documentation
Quality forms should be prepared and
filled by trained inspector
All activities, analysis, inspection and
quality level of product should be
documented
Every record should be cleared, dated
and signed by supervisor for
endorsement
Record & Documentation
Specific record book/file should be used
for documentation
Keep all information systematically for
review and auditing from time to time,
especially in any dispute on the quality
of product supplied by the supplier
CONCLUSIONS
• Improvement in quality & safety
could be done through the
implementation of GMP
• High quality and safe produce
should be beneficial to all parties
• Positive measures to improve
quality and safety of agricultural
produce should be done
continuously by all agencies/bodies
involve
Malaysian Agricultural Research and Development Institute
THANK YOU
Dr. Mohd. Salleh Punan
