Final Assignment PRODUCT DESIGN

UNIVERSITAS INDONESIA
SYNTHETIC CHICKEN MEAT
Report Assignment 5
GROUP 30
GROUP PERSONNEL:
AISYAH NUR RIDHA
(1306481991)
BUDI MULIA PANGGABEAN
(1206220586)
ERIC ADELWIN
(1206263326)
HUSNUL FAJRI
(1206224994)
PARAMITA DONA FITRIA
(1206263383)
CHEMICAL ENGINEERING DEPARTMENT

ENGINEERING FACULTY
UNIVERSITAS INDONESIA
DEPOK
2015
EXECUTIVE SUMMARY
In this chapter, we will explain about the health and safety analysis of our
product, HEMAT synthetic chicken meat. First, we will explain about the
hazard analysis method which we used in our factory product. After that, we will
explain the Material Safety Data Sheet (MSDS) of our product raw material. The
Material Safety Data Sheet (MSDS) itself is a a document that contains
information on the potential hazards (health, fire, reactivity and environmental)
and how to work safely with the chemical product. Our raw material such as
mushroom, flavor enhancer, sugar, salt, egg, etc will be explained each of their
MSDS.
The method itself which we used in hazard analysis called Hazard
Identification and Risk Assessment (HIRA). HIRA is a sheet that contains an
analysis of the prevention of hazards in an industrial plant or factory based on
aspects and activities in it.
We also need to do performance test to know how good is our product.
Performance test is the resistance of a product to the manufacturer to know
anything just things that can damage or reduce the quality of the product. Safety
of food products associated with the expiration date of the product, microbial
growth and contamination with chemicals or metals need to pass the maximum
limit for human health. To determine the factors that reduce the quality of our
food products is a way to test that is testing of microbial contamination, testing for
contamination from chemical compounds such as metal and testing of temperature
to determine how long the food product can survive.
Finally we need to tell the GHS of our product. GHS identify the
hazardous properties of chemicals that may pose a health, physical or
environmental hazard during normal handling or use. The goal of the GHS is to
identify the intrinsic hazards found in chemical substances and mixtures, and to
convey information about these hazards.
ii
Univeristas Indonesia
Table of Content
EXECUTIVE SUMMARY.................................................................................... i
CHAPTER 1 ANALYSIS OF HEALTH AND SAFETY Error! Bookmark not
defined.
1.1.
Hazard Analysis ........................................ Error! Bookmark not defined.
1.1.1.
MSDS (Material Safety Data Sheet) Analysis.................................... 12
1.1.1.1. Sugar ................................................................................................... 2

1.1.1.2. Osyter Mushroom ............................................................................... 3
1.1.1.3. Salt ...................................................................................................... 4
1.1.1.4. Flavor Enhancer .................................................................................. 4
1.1.1.5. Flour .................................................................................................... 4
1.1.1.6. Egg ...................................................................................................... 5
1.1.1.7. Garlic .................................................................................................. 5
1.1.1.8. Peanut ................................................................................................. 5
1.1.1.9. Red Onion ........................................................................................... 6
1.1.1.10. LDPE ................................................................................................ 6
1.1.1.11. Cardboard ......................................................................................... 6
1.1.2.
1.2.
HIRA (Hazard Identification and Risk Assessment) ............................ 7
Waste Treatment ...................................................................................... 12
1.2.1.
Mushroom and Garlic Waste ............... Error! Bookmark not defined.
1.2.2.
Mushroom and Garlic Wash Water ..... Error! Bookmark not defined.
1.2.3.
Equipment Sanitation Water ................ Error! Bookmark not defined.
1.3.
Regulation ................................................................................................. 15
1.3.1.
Performance Test ................................................................................ 17
1.3.1.1. Microbial Contamination Test Method ............................................ 17

1.3.1.2. Testing of metal contamination in the food with AAS ..................... 18
1.3.1.3. Method of determining the shelf life of food products ..................... 19
1.4.
Hazard Communication .......................................................................... 21
1.4.1.
Food Allergen Icons ........................................................................... 21
1.4.1.
Food Safety Icons ............................................................................... 23
CHAPTER 2 CONCLUSION ............................................................................ 26

iii
REFERENCES ..................................................................................................... 27
APPENDICES ...................................................................................................... 28
iv
List of Table
Table 1.1 Raw material composition .................................................................................. 2
Table 1.2 Parameter in calculating hazard possibility ........................................................ 8
Table 1.3 Parameter in calculating hazard effect ................................................................ 8
Table 1.4 HIRA of HEMAT factory ................................................................................... 9
Table 1.5 BPOM regulation for limit of microbial ........................................................... 15
Table 1.6 SNI for chicken nugget ..................................................................................... 15
Table 1.7 Maximum limit of microbial contamination ..................................................... 18
Table 1.8 High quality life in temperature varians ........................................................... 21
List of Figure
Figure 1.1 Plant Layout ................................................................................................... 11
Figure 1.2 Wash Water Purification in Vegetable Processing ......................................... 13
Figure 1.3 Food Allergy Warning .................................................................................... 22
Figure 1.4 Food Allergy Warning of Gluten ................................................................... 23
Figure 1.5 Safe Food Handling ........................................................................................ 23
Figure 1.6 Cooking Method ............................................................................................. 24
Figure 1.7 Potentially Hazardous Materials ..................................................................... 24
Figure 1.8 Products Packaging ....................................................................................... 25
vi
CHAPTER 1
ANALYSYS HEALTH AND SAFETY
HSE is a management system that the company's management systems are

intended to be used as a guide in the implementation of the management system
which can simultaneously accommodate HSE eligibility Management System
based on Occupational Safety and Health Permenaker No. 05/MEN/1996 on
'Application of SMK3 in the Workplace'. Guidelines mainly contains the
company's policy, as a proof of the commitment and responsibility of
management to attempt to guarantee K3, in order to improve the safety and health
protection of workers, corporate guests, partners the company's work, the
protection of corporate assets, and compliance with laws and regulations related to
SMK3.
Safety analysis includes several things, they are availability sheet MSDS
(Material Safety Data Sheets) on the properties and physic-chemical properties of
raw materials, auxiliary materials, or supporting materials the production process
used. Aside from the safety analysis is also the Safety Assessment sheet covering
sheet Hazard Identification (HAZID).
1.1. Hazard Analysis
To reduce the number of deaths, injuries and occupational diseases, in
addition to implementing the global strategy on both the K3, the authors also
conducted a hazard analysis that includes MSDS analysis and Hazard
Identification and Risk Assessment (HIRA).
1.1.1. MSDS (Material Safety Data Sheet) Analysis
A Material Safety Data Sheet (MSDS) is a document that contains
information on the potential hazards (health, fire, reactivity and environmental)
and how to work safely with the chemical product. It is an essential starting point
for the development of a complete health and safety program. It also contains
information on the use, storage, handling and emergency procedures all related to
the hazards of the material. The MSDS contains much more information about the
material than the label. MSDSs are prepared by the supplier or manufacturer of
the material. It is intended to tell what the hazards of the product are, how to use
Universitas Indonesia
the product safely, what to expect if the recommendations are not followed, what
to do if accidents occur, how to recognize symptoms of overexposure, and what to
do if such incidents occur.MSDS formats can vary from source to source within a
country depending on national requirements.
SDSs are a widely used system for cataloging information on chemicals,
chemical compounds, and chemical mixtures. SDS information may include
instructions for the safe use and potential hazards associated with a particular
material or product. These data sheets can be found anywhere where chemicals
are being used.
MSDS's provide information on:
the manufacturer or importing supplier
the product (e.g. its name, ingredients and properties)
how the product can affect your health
precautions for using or storing it safely

The MSDS from every raw material is attached in the appendix section, in
this section, MSDS composition will be explained. These table below provides the
composition of raw material of HeMat synthetic chicken meat .
Table 1.1 Raw material composition
Raw Material
Comp. (%)
Oyster Mushroom
15
Flour
50
Garlic
Peanut
Red Onion
Sugar
Salt
Egg
Flavor Enhancer
2,7
5
2,7
0,59
0,5
3
0,5
Source: Group 30 discussion
1.1.1.1 Sugar
In making our product, we use the white sugar as one of the several raw
materials. As we can see in the MSDS composition table of white sugar, the
composition of white sugar is 99% sucrose and its composition contain 0.59 %
and it will be estimated in 0.6 % of sugar. So, They are carbohydrates, composed
of carbon, hydrogen, and oxygen. There are various types of sugar derived from
different sources. Simple sugars are called monosaccharides and include glucose
(also known as dextrose), fructose and galactose. The table or granulated sugar
most customarily used as food is sucrose, a disaccharide. (In the body, sucrose
hydrolyses into fructose and glucose.) Other disaccharides include maltose and
lactose. Longer chains of sugars are called oligosaccharides. Chemically-different
substances may also have a sweet taste, but are not classified as sugars. Some are
used as lower-calorie food substitutes for sugar described as artificial sweeteners.
White sugar is non-hazardous substance and non-dangerous goods because as we
can see in chemwatch hazard ratings, white sugar only has flammability and body
contact with score one. So, the other aspect like toxicity, reactivity and chronic
has score zero. In the storage requirements for keeping white sugar, is has to keep
in dry, store away from sources of heat or ignition and observe manufactures
storing store under cover, store in well ventilated area, and handling
recommendations.
1.1.1.2. Oyster Mushroom
To emphasize our product is made from natural ingredients and raw
materials, we have decided to use oyster mushroom and the other natural
ingredients in it. Oyster Mushroom composition percentage for the synthetic
chicken meat is estimated in 15 %. Oyster mushrooms health benefits include
antioxidant and anti bacterial properties. Nutrients in these confirm the fact that
mushrooms are chock-a-block full of the good stuff. These mushrooms contain
minerals like zinc, potassium, iron, calcium, phosphorus, and vitamins like B1,
B2, C, folic acid and niacin. Also see properties of Maitake mushroom. Eating
oyster mushrooms regularly ensures that you get your daily quota of these
nutrients, especially that of vitamins. The iron content in these mushrooms is
higher than the iron present in meat a common source for your daily iron. The
potassium in oyster mushrooms is high enough to act as a preventive for heart
disease and hypertension. Mushrooms are known to absorb metals from the soil,
and oyster mushrooms tend to absorb cadmium and mercury. This could present a
health hazard and it would help to know where the mushrooms have originated, in
order to prevent it.
Because this raw material is 100% made from natural product, so we can
conclude that the oyster mushroom that we needed can be classified asa and not
reactive and non-hazardous material. For the handling, we must use gloves to
keep the mushroom sterile and away from any contaminants such as bacteria. The
storage requirements for oyster mushroom are store in cool, well ventilated place
protected from light, keep from extreme heat and away from all sources of
ignition.
1.1.1.3. Salt
From the table above, we can see that the composition of salt in HeMat
synthetic chicken meat is estimated in 0.5 %. As we have known that salt consist
of 100% pure sodium chloride. This raw material is non-flammable material, has a
good stability and there is no instability temperature.Slightly hazardous in case of
skin contact (irritant), of eye contact (irritant), of ingestion, of inhalation. For the
eye contact, we have to check for and remove any contact lenses. In case of
contact, immediately flush eyes with plenty of water for at least 15 minutes and
Cold water may be used. But this material is reactive with oxidizing agents, metal
and acids. There is no exposure limit for this material, so this material can be
classified as non-hazardous material. The storage requirements for salt are keep
container tightly closed, keep container in a cool, well ventilated area and
hygroscopic.
1.1.1.4. Flavor Enhancer
From the table above, we can see that the composition of flavor enhancer
in HeMat synthetic chicken meat is estimated in 0.5 %. enhancer is non-hazardous
material because flavor enhancer is a non-flammable material, non-reactive
material, non-oral/Parenteral Toxicity, non-dermal toxicity, non-inhalation
toxicity and normally stable even at elevated temperature and pressure. The
storage requirements for flavor enhancer are kept in closed storage, preferably
full, containers away from heat sources and protected from extreme temperature.
1.1.1.5. Flour
From the table above, we can see that the composition of flour in HeMat
synthetic chicken meat is estimated in 50 % or the biggest composition percentage
of raw material percentage This raw material is used for primary packaging for
HeMat Synthetic chicken Meat. This material is not corrosive, stable under
normal use conditions for shock, vibration, pressure or temperature and can there
is no irritant effect on the skin and eye but this material is easy to burn. Storage
requirements for flour is in dry storage. protect from heat and direct sunlight, store
container in a well ventilated position, store under dry conditions.
1.1.1.6. Egg
This raw material is used to Create an adhesive and chewy sensation
while consuming the HeMat synthetic chicken meat. From the table above, we can
see that the composition of egg in HeMat synthetic chicken meat is estimated
about 3 %.For the eye contact, we have to check for and remove any contact
lense. This material is not easy to burn, no dangerous substances are released, no
dangerous components and need gloves for contact this material this raw material
has to kept in storage below 8C. There is no special treatment to egg.
1.1.1.7. Garlic
This raw material is used to Create an adhesive and chewy sensation while
consuming the HeMat synthetic chicken meat. From the table above, we can see
that the composition of garlic in HeMat synthetic chicken meat is estimated about
2.7 %. These are raw materials that are easily damaged if just put away. We using
chiller container so that it will inhibit the growth of bacteria to inhibit spoilage.
For we use space cooling (cold room) in the form of container. This container has
termostate which can be adjusted so that the temperature will be suitable for
storage.
1.1.1.8. Peanut
This raw material is used to become one of protein source for the synthetic
chicken meat. Peanut also give some good while consuming the HeMat synthetic
chicken meat. From the table above, we can see that the composition of peanut in
HeMat synthetic chicken meat is estimated about 5 %. These are raw materials
that are easily damaged same as garlic before if just put away. We using chiller
container so that it will inhibit the growth of bacteria to inhibit spoilage. The
storage requirements for peanut are store in cool, well ventilated place protected
from light, keep from extreme heat and away from all sources of ignition.
1.1.1.9. Red Onion

This raw material is roled in giving the products taste too.While consuming
the HeMat synthetic chicken meat. From the table above, we can see that the
composition of garlic in HeMat synthetic chicken meat is estimated about 2.7 %.
These are raw materials that are easily damaged if just put away. We use space
cooling (cold room) in the form of container. This container has termostate which
can be adjusted so that the temperature will be suitable for storage. But for the
handling, we must use gloves and goggles because may be irritating for eye and
skin.
1.1.1.10. LDPE (Low-Density PolyEthylene)
This raw material is used for primary packaging for HeMat synthetic chicken
meat. This kind of plastic. LDPE is defined by a density range of 0.9100.940
g/cm3. It is not reactive at room temperatures, except by strong oxidizing agents,
and some solvents cause swelling. It can withstand temperatures of 80 C
continuously and 95 C for a short time. Made in translucent or opaque variations,
it is quite flexible, and tough but breakable. Excellent resistance (no attack / no
chemical reaction) to dilute and concentrated acids, alcohols, bases and esters.
And these are several chemical properties of LDPE:
Good resistance (minor attack / very low chemical reactivity)

to aldehydes, ketones and vegetable oils
Limited resistance (moderate attack / significant chemical reaction,

suitable for short-term use only)
to aliphatic and aromatichydrocarbons, mineral oils, and oxidizing agents
Poor resistance, and not recommended for use with halogenated

hydrocarbons
1.1.1.11. Cardboard
This raw material is used for secondary packaging for HeMat Synthetic
Meat. This material is easy to be burned but no dangerous substances are released,
no dangerous components and no need protection equipment for contact this
material. There is no special treatments to store cardboard, just need temperature
more 4OC.
1.1.2. Hazard Identification and Risk Assessment (HIRA)

A HIRA is a risk assessment tool that can be used to assess which hazards
pose the greatest risk in terms of how likely they are to occur and how great their
potential impact may be. It is not intended to be used as a prediction tool to
determine which hazard will cause the next emergency. A HIRA can help to
prepare for the worst and/or most likely hazards, save time by isolating any
hazards which can not affect the community, allow for the creation of emergency
plancs, exercises, and treaining based on the most highest risk scenarios, and the
last is to become proactive rather than just reactive.
There are four steps to create and maintain a HIRA:
1.
Hazard Identification - In this step the hazards that could impact your
community are separated from those that cannot. This requires a review of all
hazards and their causes to determine whether they may be a threat to your
community. This may require the consultation of the scientific community,
historical records and government agencies.
2.
Risk Assessment - In this step the level of risk for each hazard is examined.
This may involve speaking with hazard experts, researching past occurrences
and possible scenarios. The likelihood of the hazard occurring and the
potential impacts of the hazard on people, property, the environment, business
and finance and critical infrastructure should be examined.
3.
Risk Analysis - The information collected in the risk assessment step will be
analyzed in this step. The desired outcome of the risk analysis is the ranking
of the hazards. This highlights the hazards that should be considered a current
priority for your emergency management program.
4.
Monitor and Review - It is important to remember that a HIRA is an ongoing

process and hazards and their associated risks must be monitored and
reviewed.
The danger potential and risk identification in HIRA calculates risk level,
countermeasures, and final risk. Risk itself is defined as the combination of hazard
effect and the level of the possibility.
Risk = Hazard Possibility x Hazard Effect
The hazard possibility is divided into 3 levels which are high, medium, and low,
so does the hazard effect.
Table 1.2 Parameters in calculating hazard possibility
PARAMETER
Hazard frequency
Hazard effect
frequency
Workers
competence
HIGH
Everytime the work
done
Everytime the work
done
No experience at all in
doing the job before
MEDIUM
Once in 10 s/d
100
Once in 10 s/d
100
Less
experienced
LOW
Only once when
job is done
Only once in 100
atau more
Experienced and
Competent
Source: Reproduced from brainstorming

Table 1.3 Parameter in calculating the hazard effect
PARAMETER
Human
Resources
HIGH
MEDIUM
LOW
Dead, disability, body

disfunction, trauma,
serious injury
Huge damage towards
the instrumentation,
the production process
stopped
Medium injury,
still can continue
to do work
The damage
happened makes
the production
level decreases
Light injury
Protection Tool
Protection tool is
nowhere near the
environment where
there are many
flammable materials
Minimum
protection tool
Protection tool is
available, well
isolated and well
installed near the
hazardous area
Evacuation Time
Less than a minute
Between 1-30
minutes
More than 30
minutes
Asset
Small damage,
didnt affect
production level
10
Table 1.4 HIRA of HEMAT Factory
No.
Activities
Material and
product shipping
and loading
Transporting/mo
ving the material
to unit operation
Operating the
unit operations
Hazard
Potential
Hazard Effect
Hazard
Level
Level of
Possibility
Risk
Prevention
Final
Risk
-Material &
product spilled
and scattered
-Fall
accidentally
-Product got
damaged
-Material
spilled and
scattered
-Fall
accidentally
-Environment got
dirty
-Workers got
injured
-Company incure
losses
- Clear standard of procedure

-Usage of personal protective
equipment
- Well trained workers
- Environment got
polluted
-Workersgot
injured
- Production
process delayed
- Clear standard of
procedure
-Storing some material as
backup
- Leakage of the
unit operation
- Fire ignition
- Explosion
- Unoptimal
process
-Worker got
fainted and
injured
- Well fire extinguisher

system near the working area
- Routine maintenance of the
unit operations
- Prepare first-aid kit
- Workers low
performance
11
Table 1.4 HIRA of HEMAT Factory (Contd 1)
No.
Activities
Hazard
Potential
Hazard Effect
Hazard
Level
Level of
Possibility
Risk
Prevention
The complete usage of safety

equipment such as safety
gloves and safety shoes
- Warning sign in dangerous

area
- The complete usage of
safety equipment
- Warning sign in dangerous
Control panel
maintenance
Electrocuted
Cleaning the
plant
location/utilities
- Slipped
- Fall from
specific height
- Burnt wound &

scar
- Physical defect
- Dead
- Broken bones
- Light injury
- Dead
Instrumentations
- Fall from
- Broken bones
Maintenance
specific height
- Body
area
- Body part got
dysfunction and
injured by the
health problem
- The complete usage of
unit operation
- Dead
safety equipment
- Electrocuted
Final
Risk
After we identify the hazard, we should determine the important spots on our plant such as evacuation way, assembly point that can
be seen below.
12
Figure 1.1 Plant layout

Source: Group discussion
13
1.2. Waste Treatment

At each process in producing a product, it must produce waste, whether in
liquid, solid, or gas. This section has become an inseparable part of the production
process. Waste are substances or waste material resulting from a production
process, both industrial and domestic (household), whose presence at a particular
moment is not desired because the environment can degrade the quality of the
environment and have no economic value. Therefore, the processing of the waste
itself should be something really important for the creation of the factory and the
surrounding environment that is free from the dangers of waste. Moreover, the
purpose of processing the waste so that the company can increase the economic
value of the waste.
In the processing of industrial waste, to be dealt with very carefully
because if sewage directly discharged without being processed before, will cause
environmental pollution. In the manufacture of the product "HeMat" Synthetic
Chicken Meat, there is waste generated from the process, namely vegetables and
TVP wash water. The waste must be dealt with appropriately so that when
discharged into the environment does not cause environmental pollution.
1.2.1. Mushroom and Garlic Waste
Synthetic Chicken Meat products made from several materials, among
others, oyster mushrooms and garlic. From these materials, there are components
that are not desirable to go into the manufacturing process. Unwanted components
is called waste and must be handled appropriately. Examples of unwanted
components is the root of the oyster mushroom and the root of the garlic.
Prior to the process, unwanted components collected in the container.
Then, the contents of the container is shipped to fertilizer company to be made
into compost or organic fertilizer. This is because the nutrient-rich vegetable
waste needed for crops. In addition to the fertilizer company, leftover vegetable
waste is sent to the company used as fodder for poultry feed.
1.2.2. Mushroom and Garlic Wash Water
In the manufacturing process when entering the grinding process, the
materials to be used should be washed beforehand to prevent unwanted
contamination. Wash water is waste that needs to be addressed prior to discharge
14
into the environment. Characteristics of waste water will vary greatly depending
on the type of vegetable processed and processing techniques are used, such as
when washing, peeling, etc., and on us in the form of plant material, we used the
washing process.
The first step in wastewater treatment is to purify the washing water which
will then be used for the processing of vegetables. The steps shown in the figure
below:
Figure 1.2 Wash Water Purification in vegetable processing

Source: www.westfalia.com
In the beginning, there is a full bath area for mushrooms and garlic freshly
harvested. Mushrooms and garlic is still contaminated with various foreign
substances, such as insects, worms, humus and unwanted impurities.The high
content of organic substances in the wash water means that extensive treatment is
essential because it cannot be discharged into the sewerage system or the
15
environment in this condition. Mechanical separation of the solids is a simple and

cost-effective method of cleaning the wash water. This will automatically reduce
the cost of fresh water, and can store and dispose of residues.
A rake is the first cleaning stage in which coarse solids such as mushroom
and garlic roots or dirt are separated The pre-cleaned wash water is then rid of dirt
and sand in a sand trap; the water is further purified in a bowl strainer machine
and discharged into a settling tank. The wash water that has been treated in this
way is now pumped into the decanter. Any fine substances still contained in the
wash water are now continuously separated and discharged with a high dry
substance content. The separated solids can be collected in big tank and will be
moved into garbage disposal and the water that has been clarified by the decanter
is discharged into a retainer tank and release into the sewer.
An alternative method of purification of waste water washing treatment is
made with good infiltration. Infiltration wells are shallow wells that puts water
from or into natural aquifers beyond the river, but which has a partial layer. They
can be used to drain the catchment area or groundwater recharge, especially where
lower aquifer recharge due to low rock or soil permeability.
There charge wells will make waste from washing waster of vegetable
washing process seep into the ground. The purpose of making infiltration wells
include to improve the quality and quantity of ground water, helping to overcome
the problem of short age of water, and conserve water resources in the long term.
Infiltration wells will be created with a length of 1m diameter-2.5m and a depth of
about 2.5m. The lifetimes of absorption wells itself is usually 6-10years.
1.2.3. Equipment Sanitation Water
In addition to the wash water, there are other important aspects of the process
in the industry namely sanitary equipment. This is because the equipment used
will have direct contact with foodstuffs to be processed.
16
1.3. Regulation
Peformance test to comply with safety aspect must based on regulation
from government. So the product will easily obtain a marketing authorization
from the government for distribution. We have searched the government
regulation for synthetic chicken meat but based on source that we have done for
search, there are no government regulations for synthetic chicken meat, so we
search the regulation for processed chicken meat like nugget. The following table
is BPOM regulation for limit of microbial contamination in processed chicken
meat from Lampiran Peraturan Kepala Badan Pengawas Obat dan Makanan
Republik Indonesia HK.00.06.1.52.4011 tanggal 28 Oktober 2009.
Table 1.5 BPOM regulation for limit of microbial
Type of microbial
contamination
Type of food
processed meat and

processed chicken
meat
ALT (30C, 72 h)
APM Koliform
APM Escherichia coli
Salmonella sp
Staphylococcus aureus
Clostridium perfringens
Maximum limit
1x105 colony/g
10/g
< 3/g
negatif/25 g
1x102 colony/g
1x102 colony/g
Source: Badan Peraturan Obat dan Makanan
The type of food above is processed meat and processed synthetic meat that can
we used as based for our synthetic chicken meat product. We get references for
definition, requirements, pilot, examination, labelling and packaging for chicken
nugget that will we use for our synthetic chicken meat. The following table is
regulation from Standard Nasional Indonesia for chicken nugget.
Table 1.6 SNI for chicken nugget
No
Type of test
Unit
Requirement
Condition
1.1 Aroma
1
normal, same as lable

-
1.2 Taste
normal, same as lable
1.3 Texture
normal
17
Table 1.6 SNI for chicken nugget (Contd 1)
Type of test
No
Unit
Requirement
Another Object
% b/b
tidak boleh ada
Water
% b/b
maximal. 60
Protein
% b/b
min. 12
Fat
% b/b
maximal. 20
Carbohydrate
% b/b
maximal. 25
Calcium
mg/100g
maximal. 30
Food additive
8
8.1 Preservative
sesuai dengan SNI 010222-1995
8.2 Color
Metal contamination
9.1 Lead
maximal 2.0
9.2 Copper
9
10
maximal 20.0
mg/kg
9.3 Zinc
maximal 40.0
9.4 Tin
maximal 40.0
9.5 Mercury
maximal 0.03
Arsen contamination
mg/kg
maximal 1.0
Mocrobial contamination
11.1 Total plate count

11
colony/g
maximal 5x104
11.2 Coliform
APM/g
maximal 10
11.3 E. Coli
APM/g
<3
11.4 Salmonella
11.5 Staphylococcus aureus
/25g
colony/g
negatif
maximal 1x102
Source: Standar Nasional Indonesia
the type of test on the regulation has been elaborated on the process of SNI for
each type of test. Which has been elaborated based on SNI chicken nuggets, tests
conducted will refer to :
18
1. SNI 19-0428-1998, Hints sampling of solids

2. SNI 01-2391-1992, How to test food and beverage
3. SNI 01-2894-1992, How to test food preservatives and additives that are
prohibited for food
4. SNI 01-2896-1998, Test methods for metal contamination in food
5. SNI 01-4866-1998, Test methods for arsenic contamination in food
6. SNI 01-2897-1992, Test methods for microbial contamination
7. SNI 01-02221995, food additives
Detail SNI of each such test will in the appendix.
1.3.1. Performance Test
In the production of a product, it is important to know how the durability
of the products so that manufacturers know anything just things that can damage
or reduce the quality of the product. Safety of food products associated with the
expiration date of the product, microbial growth and contamination with
chemicals or metals need to pass the maximum limit for human health. To ensure
that our products are safe for consumption, we plan to conduct performance tests
on safety aspects, such as microbial and chemical contamination test, and test
expiration date.
1.3.1.1. Microbial Contamination Test Method
Operating condition and packaging a food production greatly influence the
spread of microorganisms (bacteria, yeasts and fungi) are present. If the operating
conditions in the production of food products meet the standards then it can
control pantogen bacteria (that cause disease) by reducing the number of spoilage
microorganisms (which cause food to go) so as to help make food safe and can
extend the shelf life of food. Methods of testing microbial contamination in
processed meat products set out in ISO 2897: 2008.
The usual method used in testing the bacterial contamination is the TPC,
MPN, and methods of enrichment. Methods Total Plate Count (TPC) is a
calculation method to determine the number of microbes contained in a product
that is grown on an agar medium in the incubation temperature and time specified.
Microbial count showed that whether or not the product is safe for consumption
19
which is adapted to the standards set by ISO. Most Probable Number method
(MPN) is an estimate of the number of microbes in a food, by gathering at a
dilution rate into three or five tubes containing liquid media design with three
replications. Results of this test is discoloration or gas formation can be observed
visually. Interpretation of the results refer to Table MPN of bacteria FDA
Analytical Manual. Enrichment method involves the isolation and identification of
microbes, and the interpretation of results (negative per gram / ml or negative per
25 grams or per 100 g / ml). The maximum limit for microbial contamination can
be seen in BPOM regulation for limit of microbial table.
1.3.1.2. Testing of metal contamination in the food with AAS
A product can be contaminated from raw materials that are less good or
from water that contains excess metal, so testing is very important metal. AAS is a
method of analysis for the determination of metal elements and metalloid based
absorption (absorbance) radiation by bebar atom of the element. A sample can be
measured when the metal content of metals in the sample have been released from
the organic material. Contamination testing methods of chemicals in products
regulated in ISO 7853: 2013.
Before measured using AAS, the sample should be prepared in advance
and should in destruction to release the metal from organic materials. Metal
deliverance usually done at high temperatures. Samples in charge until a certain
volume using demineralized water or dilute acid and subsequently measured using
AAS.
The test results are usually in the form of standard raw curve, the metal
content in the sample can be determined. Corrected sample assay using blanks.
Conclusion The test results in the form of recommendations eligible or ineligible
based on ISO. The following table maximum requirement presence of metal in a
food product
20
Tabel 1.7 Maximum limit of microbial contamination
Chemicals
Maximum Limit (ppm or mg/kg)
Arsen (Ar)
0.5
Cadmium (Cd)
0.3
Mercury (Hg)
0.03
Tin (Sn)
40
Lead (Pb)
Source: Standar Nasional Indonesia
1.3.1.3. Method of determining the shelf life of food products

Each food products, either fresh or processed / processed has shelf life
(time / resistance or power savings and durability) each are different. Shelf life is
different with the expiration date, shelf life which is more related to the quality /
quality of food (food quality), while the expiration date related to food safety
(food safety). A food product if it has exceeded its shelf life "are safe" for
consumption, but "in quality" is not guaranteed (not eligible). Expiration of a
product can be in the approximate shelf life determination method is the method
of Accelerated Shelf-Life Testing (ASLT). ASLT is a method by storing food
products in the environment that causes rapid deterioration, either in temperature
or humidity conditions higher storage space. Data quality changes during storage
is converted in the form of a mathematical model, then shelf life is determined by
extrapolation equation under normal storage conditions. Acceleration method can
be done in a shorter time with good accuracy. ASLT method that is often used is
the Arrhenius model and a model of critical water content
ASLT method Arrhenius models ASLT method Arrhenius models used to
estimate the shelf life of perishable food products by consequence chemical
reactions, such as fat oxidation, Maillard reaction, denaturation of proteins, and so
on. In general, the chemical reaction rate will be faster at higher temperatures,
which means the faster the degradation products occur. Food product shelf life
may be determined by the Arrhenius models of which are commercially sterile
canned food, powdered milk / formula, the product chips / snacks, fruit juices,
21
instant noodles, frozen meat and other food products containing high fat (fat
oxidation potential ) or that contain reducing sugars and proteins (potentially the
browning reaction).
Because the chemical reaction in general is influenced by temperature, the
Arrhenius models simulate the accelerated destruction of the product under
conditions of high temperature storage at temperatures above normal storage. The
rate of chemical reactions that can lead to damage of food products generally
follow the order of the reaction rate of the order of 0 and 1. The type of food
damage that follows a zero order reaction model is the enzymatic degradation (eg
in fresh fruits and vegetables as well as some frozen food) and fat oxidation
reaction (eg increase rancidity in foods frozen foods). While the type of damage
foodstuffs included in the order of the reaction is rancidity (eg in dried
vegetables), the growth of microorganisms, off flavor production by microbes,
damage and loss of vitamins in food quality protein (Labuza, 1982).
Order reaction equation 0
(1)
Order reaction equation 1
(2)
Where:
A
= Quality value remaining after time t
Ao
= Initial quality score
= Storage time (in days, months or years)
= Zero or one order reaction rate constants

Chemical reaction rate constant (k), either zero or one order, can be affected
by temperature. Because in general the faster chemical reactions occur at high

temperatures, the chemical reaction rate constant (k) will be greater at higher
temperatures
Psikrofilik microorganisms have the ability to grow at temperatures in the
refrigerator, especially between 0C and 5C. So long storage at these
22
temperatures both before and after freezing may result in damage to the microbe.
So try the storage temperature 18oC or lower. In the world of food technology,
reezeburn namely a change of flavors, discoloration, loss of nutrients and changes
the texture of frozen food will quickly occur if food is stored at temperatures
above minus 9C. To obtain the best results from frozen food, storage temperature
should be kept constant and not be higher than minus 17C, and should be
followed by good packaging or packaging standards for frozen foods.
Table 1.8. High quality life in temperature varians
High Quality Life (months)

Type of Food
Processed chicken
meat
-18C
-12C
-5C
12 - 18
2-3
Source: Siregar, 2010
1.4. Hazard Communication

Once a chemical has been classified, the hazard(s) must be communicated
to target audiences. As in existing systems, labels and Safety Data Sheets are the
main tools for chemical hazard communication. They identify the hazardous
properties of chemicals that may pose a health, physical or environmental hazard
during normal handling or use. The goal of the GHS is to identify the intrinsic
hazards found in chemical substances and mixtures, and to convey information
about these hazards.
The international mandate for the GHS included the development of a
harmonized hazard communication system, including labelling, Safety Data
Sheets and easily understandable symbols, based on the classification criteria
developed for the GHS.
In our HEMAT Synthetic Chicken Meat products, there are some hazard
communication that can be seen in the pictures below:
1.4.1. Food Allergen Icons
International Food Allergen Icons are easily recognizable symbols for use
in the food manufacturing and food warehouse environments that can be
recognized and understood regardless of a person's native language. The allergen
23
icons are available for use in the food industry at plant and warehouse locations
to:
Identify tools used for cleaning specific allergens.
Identify the presence of specific allergens in ingredients (i.e. place a milk

icon sticker on a pallet of bagged ingredients which contains milk powder)
Link to training material in situations where language barriers exist in

plants and can be bridged through icons used as a visual indication of the
presence of allergens.
Identification of a plant area, to indicate the presence of a specific

allergen.
For food allergen icons in our product, there are some hazard
communication that can be seen in the pictures below:
(a)
(b)
(c)
Figure 1.3 Food Allergy Warning; (a) Peanut, (b) Soy, and (c) Egg
Source: http://www.compliancesigns.com/kitchen-safety-signs.shtml
24
Figure 1.4 Food Allergy Warning of Gluten

1.4.2. Food Safety Icons

International Food Safety Icons are simple pictorial representations of
important food safety tasks that can be recognized and understood regardless of a
person's native language. Uses of the Icons include, but are not limited to:
Food safety training materials
Signs or reminders at food and beverage workstations
Food preparation and storage equipment
Recipe cards
Food packages
For food safety icons in our product, there are some hazard communication that
can be seen in the pictures below:
Figure 1.5. Safe Food Handling

25
The picture above describes the procedure in storing our products before further
processing for consumption. So, we must follow the rules in order to keep the
product safe for consumption.
Figure 1.6. Cooking Method

Source: http://www.foodprotection.org/resources/food-safety-icons/icons.php
The picture above explains that in the cooking process of our products, required
temperatures absolutely right to be safe for consumption.
Figure 1.7. Potentially Hazardous Materials

Figure 1.7 explains that our products require time or temperature control for the
safety of our products. So, in the process of taking our product into a food
product is needed to control the time or temperature can be consumed safely.
26
Figure 1.8. Products Packaging

The picture above describes the packaging of our products are LDPE (Low
Density Polyethylene), which type of plastic can be recycled back.
CHAPTER 2
CONCLUSION
To reduce the risk of the hazard in HEMAT factory we can use prevention
such as:
a. Preparing first aid-kit
b. Using well trained workers
c. Using clear standard of procedures
d. The complete usage of safety equipment
e. Routine maintenance of the unit operations
There are two sources of waste from our production process which are
derived from mushrooms, garlic and wash water. Therefore, it takes a
special treatment to process the waste into something that is not harmful,
both for the environment and living beings.
The maximum limit of the product may be contaminated with microbes by

SNI average of 1x102 colony / g.
The maximum limit of the product may be contaminated with chemical

substances Pb and Cd according to SNI by 1 and 0.3 mg / kg.
The lower the storage temperature, the product will be the longer product
durability.
In our HeMat Synthetic Chicken Meat products, there are some hazard
communication that classified into two parts, namely food allergen icons
and food safety icons. these icons already mentioned in Hazard
Communication above.
27
REFERENCES
Seider W.D., Seader J.D., Lewin D.R. Soemantri W., 2009, Product and Process
Design Principles. Synthesis, Analysis and Evaluation, Wiley and Sons Inc
Wesselingh J.A., Kiil, S. and Vigild M.E., 2007, Design and Development of
Biological, Chemical, Food and Pharmaceutical Products, John Wiley
28
APPENDICES
29
30
31
32

Final Assignment PRODUCT DESIGN

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UNIVERSITAS INDONESIA

SYNTHETIC CHICKEN MEAT

BUDI MULIA PANGGABEAN

PARAMITA DONA FITRIA

CHEMICAL ENGINEERING DEPARTMENT

Hazard Analysis ........................................ Error! Bookmark not defined.

MSDS (Material Safety Data Sheet) Analysis.................................... 12

1.1.1.1. Sugar ................................................................................................... 2

HIRA (Hazard Identification and Risk Assessment) ............................ 7

Waste Treatment ...................................................................................... 12

Mushroom and Garlic Waste ............... Error! Bookmark not defined.

Equipment Sanitation Water ................ Error! Bookmark not defined.

Performance Test ................................................................................ 17

1.3.1.1. Microbial Contamination Test Method ............................................ 17

Hazard Communication .......................................................................... 21

Food Allergen Icons ........................................................................... 21

Food Safety Icons ............................................................................... 23

CHAPTER 2 CONCLUSION ............................................................................ 26

HSE is a management system that the company's management systems are

the manufacturer or importing supplier

the product (e.g. its name, ingredients and properties)

how the product can affect your health

precautions for using or storing it safely

Source: Group 30 discussion

1.1.1.9. Red Onion

Good resistance (minor attack / very low chemical reactivity)

Limited resistance (moderate attack / significant chemical reaction,

Poor resistance, and not recommended for use with halogenated

1.1.2. Hazard Identification and Risk Assessment (HIRA)

Monitor and Review - It is important to remember that a HIRA is an ongoing

Source: Reproduced from brainstorming

Dead, disability, body

Less than a minute

Source: Reproduced from brainstorming

Table 1.4 HIRA of HEMAT Factory

- Clear standard of procedure

- Well fire extinguisher

Table 1.4 HIRA of HEMAT Factory (Contd 1)

The complete usage of safety

- Warning sign in dangerous

- Burnt wound &

- Body part got

- Clear standard of procedure

- The complete usage of

- Well trained workers

Source: Reproduced from brainstorming

Figure 1.1 Plant layout

1.2. Waste Treatment

Figure 1.2 Wash Water Purification in vegetable processing

environment in this condition. Mechanical separation of the solids is a simple and

processed meat and

Source: Badan Peraturan Obat dan Makanan

Table 1.6 SNI for chicken nugget

normal, same as lable

normal, same as lable

Table 1.6 SNI for chicken nugget (Contd 1)

tidak boleh ada

sesuai dengan SNI 010222-1995

11.1 Total plate count

Source: Standar Nasional Indonesia

1. SNI 19-0428-1998, Hints sampling of solids

Tabel 1.7 Maximum limit of microbial contamination

Maximum Limit (ppm or mg/kg)

Source: Standar Nasional Indonesia