Penggandaan Skala Produksi dan Pengembangan SOP Produk Cabai Fermentasi di CV Samara Micron Saleronell

Abstract

CV Samara Micron Saleronell menghadapi tantangan dalam pengembangan produk pasta cabai fermentasi, khususnya terkait umur simpan yang pendek, potensi kontaminasi, serta belum adanya standar operasional produksi. Proyek desain ini bertujuan untuk merancang proses produksi skala industri dan menyusun Standar Operasional Prosedur (SOP) berbasis pendekatan Failure Mode and Effect Analysis (FMEA) dan Ctitical Control Point (CCP) pada HACCP, serta melakukan analisis biaya melalui perhitungan Harga Pokok Produksi (HPP). Proses scale-up dilakukan berdasarkan neraca massa skala laboratorium yang telah divalidasi, menghasilkan kebutuhan 12 tong fermentasi berkapasitas 200 liter untuk memenuhi target produksi 1100 liter per bulan. Hasil evaluasi risiko menunjukkan tiga titik kritis kegagalan utama pada tahap pencucian, penyiapan larutan garam, dan fermentasi serta CCP pada pembersihan cabai, pencampuran larutan dan cabai, fermentasi terkontrol, dan pengemasan. SOP yang disusun mencakup 12 proses kritis dan divalidasi oleh mitra dengan nilai rata-rata 4 dari 5 pada lima aspek kelayakan. Konsekuensi dari penggandaan skala dan SOP ialah harga pokok produksi Rp 22.391/300 g dan harga jual akhir yang kompetitif untuk pasar ekspor.

CV Samara Micron Saleronell is facing challenges in the development of fermented chili paste products, particularly regarding short shelf life, potential contamination, and the absence of standardized production procedures. This design project aims to develop an industrial-scale production process and establish Standard Operating Procedures (SOP) based on a Failure Mode and Effect Analysis (FMEA) approach combined with the identification of Critical Control Points (CCP) as part of a HACCP system. A cost analysis was also conducted through the calculation of the Cost of Goods Manufactured (COGM). The scale-up process was carried out using a validated laboratory-scale mass balance, resulting in the requirement of 12 fermentation tanks with a capacity of 200 liters each to meet the production target of 1,100 liters per month. Risk evaluation identified three major critical failure points during the washing, brine solution preparation, and fermentation stages. CCP were established at chili cleaning, brine and chili mixing, controlled fermentation, and packaging. The developed SOP covers 12 critical process stages and was validated by the industrial partner, receiving an average feasibility score of 4 out of 5 across five assessment criteria. The consequence of the scale-up and SOP implementation is a cost of goods manufactured of IDR 22,391 per 300 g, resulting in a final selling price that remains competitive in the export market.