Assessment of HACCP Safety System and Good Manufacturing Practices in a Multi-product Soft Drink Bottling Plant

Abstract

Aims: To perform an evaluation of hazard analysis and critical control points (HACCP) implementation and good manufacturing practices (GMP) in a multi-product soft drink company in Nigeria. Study Design: Semi experimental study combined with survey. Place and Duration of Study: Study was carried out in December 2015 in a bottling facility in south-east Nigeria. Methodology: HACCP audit and failure mode and effect analysis (FMEA) were performed and scored after responses to specific questionnaires were obtained from plant staff. The GMP compliance (%) for corrective action taken on operational audit issues was determined by scoring the number of issues corrected over the total advised. Microbial quality of products was verified using membrane filtration and fill content was established with a 500 mL measuring cylinder. The beverage brix (%) was determined with a density meter and CO2 content (g/L) was ascertained using a CO2 tester according to manufacturer’s instructions. Traceability was performed by using the date code stamped on the finished bottled products as a reference point. Results: The average percentage conformity was 90% for HACCP implementation and 74% for functioning of HACCP in practice. Application of FMEA to the audit showed that minor risks existed in HACCP implementation whereas moderate risks were found in functioning of HACCP in practice.  Evaluation of GMP compliance showed that raw materials and intermediate products were traceable and a review of previous audits which covered HACCP pre-requisite programs showed 90-100% compliance with corrective action required. Checks on microbial quality, brix, fill content and carbonation showed results that were within prescribed limits which indicated that safe products were manufactured. Conclusion: The seven principles and 12 implementation steps of the HACCP system were firmly established and GMP was effective. However, the maintenance of the HACCP structure during operations requires improvement.