QUALITY CONTROL OF TOMATO KETCHUP

AT PT SPARINDO FOOD
TANGERANG

Name: Jordan Dharma Karya

ID: 00000013287
Internship Supervisor: Natania M. Eng.
 Internship Timeline and Location
• The internship program was held from May 14th, 2018 to June 26th, 2018 at
PT Sparindo Food.
• The internship program was carried out every week from Monday to Friday,
from 8 a.m. until 4 p.m.
• The company is located at Jalan Raya Serang KM. 13.8, kecamatan Cikupa –
Tangerang, Banten 15710.
 Company’s Profile
• This company started in 1980 as PT Megah Sari Howardi.
• It changed to PT Sparindo Food in the year of 2006.
• The company produces tomato ketchup, chili sauce, BBQ sauce, and
traditional sauce.
• Vision of the company:
 Producing high quality foods that can be trusted by the consumers across Indonesia. PT
Sparindo food applies the method of high quality, hygienic, and up to date methods to
produce high quality, safe, and tasty food products.
 Human Resources
• There are currently 89 persons worked at PT Sparindo Food.
• The employees are divided into staff, Harian Lepas, and Borongan.
• Working hour:
1. Operational employee: Monday-Saturday (08:00 – 16:00 & 16:00 – 00:00)
2. Non-Operational employee: Monday-Friday (08:00 - 16:00)
• The staffs and Harian Lepas employees receive wages, bonuses for special occasion,
day-off and health insurance.
• Borongan employees only receive wages based on the working time
Organizational Structure
 Production of Tomato Sauce

Cooking and
Raw material Pasteurization Filling Packing
preparation
• CCP
Quality Control of Raw Material
and Packaging
 Raw Material
• The main material is consisted of tomato
paste, starch, sugar, salt, garlic, and
flavoring.
• The supporting material is consisted of
preservatives, vinegar, and colorants.
• The PPIC will check the date of arrival,
the number of batch, name of the
material, supplier, and the country of
origin, production date, and expired date
• The weight of the raw materials is also
checked by the warehouse and production
division to make sure that the weight is in
accordance with the label.
• Color, texture, and smell are observed to
find any damages.
• A sample of tomato paste is taken from
each batch of the raw materials to analyze
the properties of the raw materials, which
are total solids, pH, and salt content.
 Packaging Materials
• Two types of packaging: 9 grams
sachet roll and 1 kg plastic roll.
• The 9 grams sachet primary packaging
is made from a mixture of PET, INK,
adhesive, PE, Aluminum, and
(LLDPE).
• The 1 kg plastic roll is made of
mixture of Nylon (NY), INK,
adhesive, and (LLDPE).
• The secondary packaging is made from
polypropylene and polypropylene.
• The requirements of the packaging:
date of arrival, number of batch,
supplier, country of origin, and
production date. After that, the
Certificate of Analysis, and condition
of the packaging.
Quality Control of Production
Process
 Raw Material Preparation
• Raw Materials: tomato paste, starch, • the pH and total solids of tomato
sugar, salt, garlic, flavoring, paste will be checked by QC.
preservatives, vinegar, and
colorants.
• The formulation of the raw
materials is decided by the Research
and Development division.
 Mixing
• The machines used are hopper,
liquid and paste raw materials
mixing tank, premix tank, and
mixing tank.
• Tomato sauce premix is sampled
per batch, then it is checked for the
properties, such as total solids, pH,
viscosity, and salt content.
• If the result does not meet the
standard value, the mixture will be
applied with different treatments,
such as adding the mixture with
additional raw materials or water
and disposing the premix sauce.
oBrix 15 – 16 o
pH 3.6 – 3.9
Viscosity 0.3 – 0.4 Pa.s

Salt Content 5.0 – 6.5 %

 Cooking and Pasteurization
• The Quality Control division will • During the cooking and
check the hygiene of the machine pasteurization process, critical
to prevent the contamination of control points are applied to
the product. prevent contamination.
Air Supply Pressure 6 – 8 Bar
• The parameters of the observation Steam Supply Pressure 3 – 8 Bar

are cleanliness, occurrence of chili Hot Water Pressure 2 – 4 Bar

or tomato paste clumps, and Temperature Alarm Setting

Product Holding Temperature

108 – 110 oC

108 – 110 oC
dryness. Product Cooling Temperature 40 – 55 oC

Pressure Pump 10 – 15 Bar

Speed Motor Pasteurizer 900 – 1200 RPM

 Filling and Packing
• . The quality control division will • The quality control will also do a
observe the availability of the tear leak test and stability test.
cut and expired date for every • The appearance of the packaging is
filling machine in every hour of also checked by the quality control
production. division. The packaging is checked
• The expired date’s format is whether the filling machine cut the
DDMMYY-Production code. packaging at the cutting line or not.
Quality Control of Finished Goods
 Finished Goods
• The tomato sauce products have a
shelf life of one year, which starts
from the day of filling.
• The quality control division will
observe and analyze the sample of
each filling machine.
• The quality control division will
analyze the properties of the tomato
sauce, which are viscosity, pH, salt
content, total solids, and
microbiological properties.
oBrix 18 – 20 o

• The quality control division observes

the appearance and the taste of the pH 3.6 – 3.9

tomato sauce whether it is in Viscosity 70 – 80 Pa.s

accordance with the standard or not.
Salt Content 5.0 – 6.5 %
 Storage and Distribution
• Types of storage area: raw material
warehouse and finished products
warehouse, which are located on the
first floor.
• The raw materials and finished
products are stored at room
temperature. The humidity of the
warehouses is not regulated, the
humidity of the warehouses is affected
by the environment humidity.
• The raw materials stored in barrel are
put on a metal racks, while the raw
materials stored in carton are stacked
on pallets.
• The raw materials that are kept in the
warehouse can be moved to the
production area by using forklift.
• PT Sparindo Food applies the First In
First Out (FIFO) system.
 Distribution system
• The distribution system of PT • The products packaging and the
Sparindo Food is based on the pre- transportation must be checked.
order system. The products pre-order quantity
• PT Sparindo food distributes their must be the same with quantity that
products to groceries, restaurant, is checked before the distribution.
and hotel. There also must be expired date
and code packing on every product.
 Premises and Facilities
• The factory is located on industrial • There are also several air ducts applied
area, far away from residential area. in each area of the factory to provide
air circulation and cool air.
• The walls of the factory are high, with
the ventilation at the top of the walls, • There are also toilets, changing room,
to prevent contamination. cleaning area and hand washing
facilities in the office and the factory
• There are enough lights to illuminate to provide hygiene for the workers.
the factory properly. The walls and the
ceiling are high enough to provide
space for the production area and
warehouses
 Personnel Hygiene
• The leaders of each section will examine
the workers with the requirements that are
provided.
• General rules: smoking is not allowed,
bringing food and beverages to the
production area is not allowed, bringing
phone and other electronic devices to the
production area is not allowed, and
washing hand and using sanitizer is
required.
• The requirements:
1. Workers in a good health condition.
2. Wearing a complete uniform that is provided.
3. Wearing a headwrap that is provided.
4. Wearing special shoes that are provided.
5. Male workers must have short hair.
6. Male workers must not have a goatee.
7. Male workers must not have a thick moustache.
8. Nails are in a clean and short condition.
9. Workers must not wear accessories.
 Sanitation of Equipment and Machinery
• The quality control division will • The steps of CIP Program:
conduct the Cleaning In Place 1. 1.5% NaOH
(CIP) program on the machines
such as pasteurizer machine and the 2. 80oC hot water
filling machine. 3. Metacid
• The CIP program is done saily and 4. 95oC hot water
weekly.
5. Peroxy (0.3%)
 Sanitation of Factory Area
• The cleaning procedure is done • The sanitation of the plant is
daily and weekly. observed and checked by the
• The cleaning is done in the Quality Control division.
beginning of first shift, before the • Each area of the plants have
production process starts and at the different parameter to be observed.
end of second shift.
 Pest Control
• The pest control program of PT • The pest control practices:
Sparindo Food is done by external
pests control company. 1. Residual spraying
• The pest control program is done once 2. cold fogging
a week. 3. mist blowing
4. thermal fogging
5. rat baiting
6. insect baiting
7. inspection.
 Traceability and Recall
• The consumers can file a complain • The recalled products can either be
to the company, if the products reworked and pasteurized again or
received in a bad condition. disposed.
• The batch of products with the • The recalled products will be
same production code will be analyzed by the Quality Control
recalled from the distributor or Department, then they are
consumer. compared with the retained sample.
 Waste Management
• Waste management is the disposal
of expired, broken, contaminated
raw materials, products, packagings,
plastics, carton.
• The product is diluted with water,
then it is disposed into sewage
system.
• The liquid waste is disposed directly
into sewage system.
• Plastic wastes are disposed by
crushing the plastic with a crusher
machine. Carton wastes
management is done by selling it to
local recycling company.
 Problems Occurred and Solution
Problems
The tomato sauce produced did not fill the standards.
The occurrence of impurities in the product
Puffed up sachet
The packaging of the product, especially the sachet
product often does not have a tear cut and expired
date on the packaging.
Solution
The workers should have checked the weighing of raw
materials for several times, before using it for the
production.
Raising the workers awareness during the raw material
preparation and the workers should have inspected
and cleaned the machine thoroughly
Increasing the cleanliness of the filling machine and
pasteurizer machine during the CIP program
Doing a regular maintenance to the filling machine.
 Conclusions
• The quality control process of PT • Overall, the company has conducted
Sparindo Food covers all the the quality control process well.
production process from the receiving
of raw materials until the distribution
of the products.
• The sanitation and hygiene of the
workers, equipment and area are
implemented based on GMP and
SSOP, which ensure the quality of the
products.
 Suggestions
• Implement an enclosed filling system on the filling area and heat treatment
during filling process, to prevent contamination of the products.
• Implement filter before the filling process, to prevent impurities occurrence
in the final products.
• Implement new maintenance system to the filling machine, to maintain the
stability of the machine.
• Improve the waste management system of the company.