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Homework answers / question archive / Assignment Scope:<br/>A bread manufacturing facility is investigating expansion of their site to include production of gluten-free bread

Assignment Scope:<br/>A bread manufacturing facility is investigating expansion of their site to include production of gluten-free bread

Health Science

Assignment Scope:<br/>A bread manufacturing facility is investigating

expansion of their site to include production of gluten-free bread. They will begin with introduction of a white bread product. Factory management would like to know how they might need to change the operations and quality management systems to incorporate this new product without cross- contamination
In this assignment you might use the following resources to help collect information to construct a Quality Management System (QMS) for the bread manufacturing facility and their new product:
• GMP principles
• ISO9000:2016
• ISO22000
• HACCP principles
• Quality control statistical tools
• Appropriate Food Standards
References that may help you:
• Lecture notes and resources
• AS/NZS ISO9000:2016
• ISO22000:2005 or 2018
• http://www.foodstandards.gov.au/code/Pages/default.aspx
• Mortimore, S and Wallace, C., (2013), HACCP - a practical approach: 3rd
edition, Springer, New York. (Particularly the ice cream case study in
Chapter 6)
• Ali, I 2003, Food Quality Assurance: Principles and Practices, CRC Press
• Vasoncellos, J.A., 2003, Quality Assurance for the Food Industry: A
Practical Approach, CRC Press
• Lim, S.A.H. and Antony, J. (2019) Statistical Process control for the food
industry: a guide for practitioners and managers
Task 1: Process flow chart to factory layout
A laboratory scale process flow chart for the gluten-free white bread is outlined in Figure 1. Using GMP principles and the appropriate standard from the FSANZ Food Standards code (think about this!), design a factory annexe layout for the gluten-free bread production line that may suit this process. Use the lecture template to guide you but alter it for this scenario.
You will first need to convert this lab scale bench process to a large scale factory process including receiving of goods (packaging and ingredients,
other materials), quality control, dispatch and other factory-based activities. Ensure that you allow appropriate storage and receiving facilities for the different ingredients as well as the finished products. Also ensure that there will be no contamination with gluten-containing bread.
145 g white flour + 85 g tapioca starch + 92 g potato starch + 60 g millet flour + 25 g flaxseed meal + 9 g xanthan gum +
5 g baking powder + 6 g salt
60 mL olive oil + 75 g egg white + 6 g vinegar
25 g sugar +
7 g yeast +
300 g warm water
Yeast Proofing for 5-10 minutes
Mixing for 1-2 minutes on low speed
Mixing for 1-2 minutes on medium speed
Proofing (45- 60 minutes)
Baking at 175°C for 60- 65 minutes
Figure 1: Lab scale process flow chart
Task 2: HACCP analysis
Using HACCP principles identify any critical control points in the gluten- free bread factory process and (where possible) how control might be implemented. Use an audit table approach as shown in lecture case studies to help guide you. Also refer to the appropriate food standards.
1. Based on the flow diagram for the process evaluate each step for potential:
a. Chemical hazards
b. Microbiological hazards c. Physicalhazards
2. Use a decision tree to determine if the step is a CCP and explain why 3. Where possible describe where additional steps or precautions have
helped overcome a hazard not previously thought of.
Task 3: Process control for quality
For quality control it was determined that the gluten-free bread must have a dough volume increase of between 3 and 3.6 to meet the sensory and quality requirements of the product. Once the factory started running, a single batch run on one of the days of production had the following data was recorded with samples collected and tested every half hour during the day shift.
Table 1: Process dough volume increase performance data
Samples xi1
1 3.1
2 3.4
3 3.9
4 3.4
5 3.6
6 3.2
7 3.3
8 3.2
9 3.3
10 3.1
11 3.6
12 3.8
13 5.0
14 3.7
15 3.9
16 3.7
17 3.2
18 3.9
19 3.0
20 3.2
21 3.4
22 3.4
23 3.1
24 3.5
You need to:
xi1
3.8 3.4 3.3 3.5 3.8 3.5 3.6 3.9 3.3 3.4 3.2 3.2 3.6 3.5 3.2 3.5 3.6 3.2 3.9 3.6 3.4 3.9 3.7 3.9






xi1


xi1
Ri




3.6
3.9
3.9
3.7


3.5
3.9




3.9
3.9
4.0


3.8






3.9
3.9
3.3


3.1




3.7


3.3




3.1
3.5
3.8
3.5




3.9
3.8
3.0


3.8




3.6


3.1






3.5
3.8
3.4


3.5




3.3
3.3
3.8
3.7




3.9
3.2
3.9


3.5




3.9


3.1






3.9
3.4
3.5


3.2




3.6
3.6
3.8
3.7


1. Construct an X bar chart
a. Determine the average line
b. Determine the Upper Control Limit line c. DeterminetheLowerControlLimitline
2. Comment on both of the following:
a. Whethertheprocessisincontrolfromastatisticalpointofview b. Whether the process is in control from a food quality and
sensory point of view
3. Discuss how any quality issues may be resolved from a process point
of view.

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