HACCP Plan Brief for the Production of Chicken and Vegetable Pies
Product and Process Description:
Raw materials, including diced raw chicken meat and prepared diced mushrooms and dry ingredients are obtained from suppliers and delivered directly to the site in temperature controlled vehicles, as appropriate. On delivery, raw materials are placed into storage, the chicken meat and mushrooms being stored in chill stores at 1-5ºC. Chicken meat is stored in a chill store specifically used for the storage of raw meat to ensure segregation from other materials.
Pies are produced on a daily basis in accordance with the production plan. Pie filling is manually prepared in accordance with the recipe/formulation sheet in 25kg batches. Diced chicken meat is browned in vegetable oil in a steam jacketed kettle to seal the surface of the meat. On completion, the diced mushrooms are added and browned. A stock is prepared in the kettle using vegetable bouillon, water, seasoning and herbs and brought to boiling point before being. simmered for 45 minutes. The stock, chicken meat and mushroom pie filling mixture is then thickened with a paste made from modified starch and water. The batch is held hot in the kettle at 75-80ºC until required for transfer to the production line. When required, the pie filling is poured into stainless steel wheeled tote bins, covered with a lid and taken to the depositor on the pie making line where it is pumped into the depositor hopper.
Pastry is prepared from a dry pastry mix supplied in 25kg sacks, Required amounts are manually dispensed into the hopper of a mixer (batches are normally 50-60kg in size) with any offcuts from previous batches (pastry offcuts are collected from the line automatically, stored under refrigeration (1-5ºC) and must be used within 24 hours or disposed of) and automatically blended with water under the control of the mixer software. Prepared pastry mixes are tipped into stainless steel tote bins and lidded before being transferred to one of two pastry sheeters where the bins are hoisted and the mix transferred to the hopper for the sheeter. For production of the bases of the pies, pastry is sheeted out and conveyed over ‘moulds’ (previously fitted with a pre-formed aluminium cases) before being ‘pressed’ into the base of the moulds.(blocking). The lined moulds then pass under the depositor where pie filling is deposited into the pie base. Pastry from the other sheeter is conveyed over the top of the pies as they leave the depositor and then laid mechanically over the open, filled pie bases before passing through a sealing and cutting device which forms a seal between the pastry in the pie base and the pastry of the pie lid before the pies are cut out and the offcuts and pies separated. Offcuts are collected in a stainless steel tote bin which, when full, is lidded, labelled with the contents and transferred to a chiller until required for adding back into the pastry mix, as described previously.
Pies are transferred by conveyor, through an egg based glaze spray (made from a glaze powder manually mixed with water using a stainless steel whisk) before being baked through a continuous band oven. The cooking temperature is set to achieve an internal temperature within the pies of a minimum of 77ºC but there is an adjustment possible on belt speed to achieve the correct product colour at the end of the baking process. Post baking, pies are transferred on conveyor into a blast chilling tunnel, where chilling brings the temperature of the product down to <10ºC over a period of 45 minutes. Post cooling, products are automatically removed (with the aluminium case) from the moulds and conveyed to a flow wrapping machine, where they are wrapped, labelled and date coded ( Packing date +10 days) before being packed by hand into cardboard outer transit cases. Completed outer cases are stacked onto pallets and taken to a chill store for storage until ready for distribution by a third party haulier.
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