Quality Plan Design to Minimize Defects in Dried Banana Production

Abstract

Sugar bloom, the crystallization of sugars on the surface of dried bananas, is a recurring quality defect that affects the visual appeal and perceived freshness of Hillkoff Co., Ltd.'s dried banana products. This study aimed to develop a quality plan and revised standard operating procedure (SOP) to reduce sugar bloom occurrence and improve overall product stability. Field observations and focus group discussions were conducted to identify key issues across the production line. Root cause analysis revealed that inconsistent post-drying storage conditions and ineffective soaking treatments were the primary contributors to sugar bloom formation. Two interventions were proposed and tested: the addition of 0.35% citric acid in the soaking solution and controlled cold storage at 5°C and 65% relative humidity. Both methods showed significant effectiveness in minimizing sugar crystallization over a 45-day storage period. A quality scoring system was also developed to quantitatively assess sugar bloom severity. Results indicated that implementing these strategies can greatly enhance product consistency, extend shelf life, and reduce waste. The proposed quality plan provides a practical model for continuous improvement and can be adapted by other small- to medium-scale food producers facing similar post-processing quality challenges.