Use Of Hazard Analysis Critical Control Point Principles
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De vel opm ent of HACCP pr ocedur es for the pr oducti on of so y based foods and thei r eval ua ti on (RP F-I II).
A.P.Gandhi
08/20/09
Gandhi
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Project No:
583
Time spent:
25%
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Objectives i.To develop HACCP procedures for the production of different soy based foods. ii. To test the developed procedures with a few soy-based foods such as full fat soy flour, soy milk, soy paneer (tofu), soy nuts and soy sprouts. 08/20/09 Gandhi 3
iii. To document the developed procedures and final report writing.
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Technical program The drafting of procedures include identification of hazards and control measures, determination of critical control points, 08/20/09
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preparing
the decision tree, establishing the critical limits and marketing procedures,
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finding
the corrective action, responsibilities and verification procedures ,
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preparation
of HACCP chart documentation & record keeping for the soy based foods. 08/20/09
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Soy products: Flour (Full fat soy flour and medium fat soy flour). Soymilk and analogs (Soymilk (Plain) and, Soy paneer) ,Bakery products (Cookies and bread), Soy nuts,Soy sprouts, and Soy protein isolates . 08/20/09
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Date of Start: April 2007 Date of Completion: March 2009
The technical program was accomplished as approved.
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Various soy based foods like full fat soy flour, medium fat soy flour, soy milk, soy paneer(tofu), soy bakery products ,soy nuts were developed besides the protein isolates which find place in food formulations/pharmaceutical applications. These foods are to be produced with utmost safety.
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The availability of safe food improves the health of people and is a basic human right. Safe food contributes to health and productivity and provides an effective platform for development and poverty alleviation.
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The poor are the most susceptible to ill health. Trends in global food production, processing, distribution and preparation present new challenges to food safety.
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Food safety must be addressed along the entire food chain by measures based on sound scientific information at both national and international levels. Food safety is an essential public health issue.
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Food safety programs are increasingly focusing on a farm- to –table approach as an effective means of reducing food borne hazards. This holistic approach to the control of food related risks involves consideration of every step in the chain . 08/20/09 Gandhi 15
Now with the introduction of food quality and safety systems, HACCP has become synonymous with food safety. HACCP is a tool for process control to overcome the microbial hazards. The ultimate goal is improvement of public health.
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It is a world wide recognized systematic and preventive approach that addresses biological, chemical and physical hazards through anticipation and prevention rather than through end-product inspection and testing and thereby reducing the food borne illness.
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Prior to application of HACCP the production of soy based should be according to Codex General Principles of Food Hygiene, the appropriate Codex Codes of practice and appropriate food safety legislation.
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Good Agricultural Practices Primary production Environmental hygiene: Should not be carried out on in areas where the presence of potentially harmful substances would lead to an un acceptable level of such substances. 08/20/09
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Hygiene production of food sources: Producers should as far as practicable implement measures to Control contamination from air, soil, water, feed stuffs, fertilizers, pesticides, veterinary drugs or any other agent used in primary production. 08/20/09
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Control plant and animal health. Protect food sources from faecal and other contamination. Handling, storage and transport: Procedures should be in place to sort food and food ingredients to segregate material which is evidently unfit for human consumption.
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Dispose of any rejected material in a hygienic manner. Protect food and food ingredients from contamination by pests, chemical, physical or microbiological contaminants.
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Cleaning, maintenance and personnel hygiene at primary production: Appropriate facilities and procedures should be in place to ensure that Any necessary cleaning and maintenance is carried out effectively. An appropriate degree of personnel hygiene is maintained. 08/20/09
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Good Manufacturing Process Establishment of Design and facilities Location: Establishments They should be located away from Environmentally polluted areas and industrial activities which pose serious threat of contaminating the food. 08/20/09
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Areas subject to flooding unless sufficient safe guards are provided. Areas prone to infestation of pests. Areas where wastes, either solid or liquid can not be removed effectively.
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Equipment: Equipment should be located so that it Permits adequate maintenance and cleaning. Functions in accordance with its intended use. Facilitates good hygiene practices including monitoring. 08/20/09 Gandhi 26
Premises and rooms: Design and lay out Where appropriate the internal design and lay out of food establishments should permit good food hygiene practices including protection against cross contamination between and during operation of food stuffs. 08/20/09
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Internal structures and fittings: The surfaces of walls, partitions and floors should be made of impervious materials with no toxic effect in intended use. Walls and partitions should have a smooth surface up to a height appropriate to the operation. 08/20/09
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Floors should be constructed to allow adequate drainage and cleaning. Ceilings and overhead fixtures should be constructed and finished to minimize the build up of dirt and condensation and the shedding of particles.
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Window should be easy to clean, be constructed to minimize the build up of dirt and where necessary be fitted with removable and cleanable insect proof screens.Where necessary windows should be fixed.
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Doors should have smooth, non absorbent surfaces and be easy to clean and where necessary disinfect. Working surfaces that come into direct contact with food should be in sound condition, durable and easy to clean.
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Equipment: They can be adequately cleaned, disinfected and maintained to avoid the contamination of food. Equipment and containers should be made of materials with no toxic effect in intended use. 08/20/09
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Where
necessary equipment should be durable and movable or capable of being disassembled to allow for maintenance, cleaning, disinfections, monitoring.
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Food control and monitoring equipment: The equipment used to cook, heat treat, cool, store or freeze should be designed to achieve the required food temperatures as rapidly as necessary in the interests of food safety and suitability and maintain them effectively. 08/20/09
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Containers for waste and inedible substances: Containers for waste, by products and inedible or dangerous substances should be specifically identifiable, suitably constructed and where appropriate made of impervious material. 08/20/09
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Containers
used to hold dangerous substances should be identified and where appropriate, be lockable to prevent malicious or accidental contamination of food.
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Personnel hygiene facilities and toilets: Where appropriate adequate means of hygienically washing and drying hands, including wash basins and a supply of hot and cold water. Lavatories of appropriate design. Adequate changing facilities for personnel. 08/20/09
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Temperature Control: Adequate facilities should be available for heating, cooling, refrigerating and freezing food, for storing refrigerated or frozen foods, monitoring the food temperatures and when necessary controlling the ambient temperatures to ensure the safety and suitability of food. 08/20/09
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Air Quality and ventilation: Adequate means of natural and mechanical ventilation should be provided to Control ambient temperatures. Minimize the air borne contamination of food. Control odors. Control humidity where necessary. 08/20/09
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Facilities: Water supply An adequate supply of potable water with appropriate facilities for its storage, distribution and temperature control should be available where necessary to ensure the safety and suitability of food. 08/20/09
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Potable water should be as specified in WHO Guidelines. Non potable water shall have a separate system and shall be identified.
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Drainage and waste disposal: Adequate drainage and waste disposal systems and facilities should be provided.
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Cleaning: Adequate facilities, suitably designated should be provided for cleaning the food utensils and equipment. Such facilities should have an adequate supply of hot and cold potable water where appropriate. 08/20/09
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Control of operation Adequate time, temperature or humidity controls. Food grade packaging. Potable water supplies. Maintenance of equipment. 08/20/09
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Maintenance and Sanitation Adequate level of maintenance of an establishment as well as efficient practices for cleaning, waste management and pest control.
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Personal Hygiene Health Status: People known or suspected to be suffering from or to be a carrier of a disease or illness likely to be transmitted through food should not be allowed. 08/20/09
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Illness and injuries:
Conditions which should be reported include jaundice, diarrhea,vomiting, fever, sore throat with fever, visibly infected skin lesions and discharges from the ear , eye or nose.
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Personnel cleanliness: They should wear suitable protective clothing, head covering and footwear.Cuts and wounds where personnel are permitted to continue working should be covered by suitable water proof dressings. 08/20/09
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Personnel should always wash their hands -at the start of food handling activities. -Immediately after using the toilet. -After handling raw food or any contaminated material.
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Personal Behavior: People engaged in food handling activities should refrain from behavior which could result in contamination of food like smoking, spitting, chewing or eating and sneezing or coughing over unprotected food. 08/20/09
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Visitors: Visitors to food manufacturing, processing or handling areas should where appropriate wear protective clothing and adhere to other personal hygiene.
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Transportation Method of transportation should be such that measures are taken to prevent any contamination or deterioration of the product. Controlled environments like chilled, frozen or stored under specific humidity levels. 08/20/09
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Containers need to be maintained in good condition and be easy to clean. Designed specifically for food use only.
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Training All food handlers should be trained in personal hygiene, and should be supervised by the trained supervisors.
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Product information and consumer awareness: The product should be accompanied by adequate information. All batches should be identified by a batch or lot number to allow trace ability of the commodity if required. 08/20/09
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Management commitment is necessary for implementation of an effective HACCP system.
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No relevant published data is available on the usage of HACCP in the production of soy-based foods globally too.
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Hence efforts were made to draft the HACCP procedures for the production of different soy based foods.
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Food safety in today’s’ world is paramount. HACCP programmes go a long way to ensuring this food safety. We rely on food to nourish and sustain us. We want food that is appealing and pleasurable to eat.
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We need food that will not cause us injury or illness or severe cases cause death. There are members of our community- the young, the not so young, the immunocompromised and those who are susceptible to allergies and intolerances that rely on us in the food industry to supply them with safe food.
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May our efforts be not in vain as we meet this responsibility each day?
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PR INC IPLE S OF TH E HAC CP SYS TEM
PRINCIPLE 1 Conduct a hazard analysis. PRINCIPLE 2 Determine the Critical Control Points (CCPs). PRINCIPLE 3 Establish critical limit(s). 08/20/09
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PR IN CIPL ES OF T HE H ACCP SY STEM
PRINCIPLE 4
Establish a system to monitor control of the CCP. PRINCIPLE 5
Establish the corrective action to be taken when monitoring indicates that a particular CCP is not under control. 08/20/09
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PRINCIPLE 6
Establish procedures for verification to confirm that the HACCP system is working effectively. PRINCIPLE 7
Establish documentation concerning all procedures and records appropriate to these principles and their application. 08/20/09
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APP LI CA TI ON
1. Assemble HACCP team
The food operation should assure that the appropriate product specific knowledge and expertise is available for the development of an effective HACCP plan.
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Optimally, this may be accomplished by assembling a multidisciplinary team. Where such expertise is not available on site, expert advice should be obtained from other sources. 08/20/09
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The scope of the HACCP plan should be identified. The scope should describe which segment of the food chain is involved and the general classes of hazards to be addressed (e.g. does it cover all classes of hazards or only selected classes).
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2. Describe product
A full description of the product should be drawn up, including relevant safety information such as: composition, physical/chemical structure (including Aw, pH, etc.), microcidal/static treatments (heat-treatment, freezing, brining, smoking, etc.), packaging, durability and storage conditions and method of distribution. 08/20/09
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3. Identify intended use
The intended use should be based on the expected uses of the product by the end user or consumer. In specific cases, vulnerable groups of the population, e.g. institutional feeding, may have to be considered. 08/20/09
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4. Construct flow diagram
The HACCP team should construct the flow diagram. The flow diagram should cover all steps in the operation. When applying HACCP to a given operation, consideration should be given to steps preceding and following the specified operation. 08/20/09
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5. On-site confirmation of flow diagram
The HACCP team should confirm the processing operation against the flow diagram during all stages and hours of operation and amend the flow diagram where appropriate.
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6. List all potential hazards associated with
each step, conduct a hazard analysis, and consider any measures to control identified hazards. The HACCP team should list all of the hazards that may be reasonably expected to occur at each step from primary production, processing, manufacture, and distribution until the point of consumption. 08/20/09
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The HACCP team should next conduct a hazard analysis to identify for the HACCP plan, which hazards are of such a nature that their elimination or reduction to acceptable levels is essential to the production of a safe food. 08/20/09
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7. Determine Critical Control Points There may be more than one CCP at which control is applied to address the same hazard. The determination of a CCP in the HACCP system can be facilitated by the application of a decision tree which indicates a logic reasoning approach. 08/20/09
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Application of a decision tree should be flexible, given whether the operation is for production, slaughter, processing, storage, distribution or other. It should be used for guidance when determining CCPs. 08/20/09
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8. Establish critical limits for each CCP . Critical limits must be specified and validated if possible for each Critical Control Point. In some cases more than one critical limit will be elaborated at a particular step. 08/20/09
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Criteria often used include measurements of temperature, time, moisture level, pH, Aw, available chlorine, and sensory parameters such as visual appearance and texture.
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9. Establish a monitoring system for
each CCP. Monitoring is the scheduled measurement or observation of a CCP relative to its critical limits. The monitoring procedures must be able to detect loss of control at the CCP. 08/20/09
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Further, monitoring should ideally provide this information in time to make adjustments to ensure control of the process to prevent violating the critical limits. Where possible, process adjustments should be made when monitoring results indicate a trend towards loss of control at a CCP.
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10. Establish corrective actions . Specific corrective actions must be developed for each CCP in the HACCP system in order to deal with deviations when they occur.
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The actions must ensure that the CCP has been brought under control. Actions taken must also include proper disposition of the affected product. Deviation and product disposition procedures must be documented in the HACCP record keeping.
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11. Establish verification procedures .
Verification and auditing methods, procedures and tests, including random sampling and analysis, can be used to determine if the HACCP system is working correctly. The frequency of verification should be sufficient to confirm that the HACCP system is working effectively.
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12. Establish Documentation and Record Keeping . Efficient and accurate record keeping is essential to the application of a HACCP system. HACCP procedures should be documented. Documentation and record keeping should be appropriate to the nature and size of the operation. 08/20/09
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TRA INI NG
Training of personnel in industry, government and academia in HACCP principles and applications, and increasing awareness of consumers are essential elements for the effective implementation of HACCP.
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As an aid in developing specific training to support a HACCP plan, working instructions and procedures should be developed which define the tasks of the operating personnel to be stationed at each Critical Control Point. Cooperation between primary producer, industry, trade groups, consumer organizations, and responsible authorities are of vital importance .
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Applicat ion of HAC CP in S oy foods
Various soy-based foods were prepared with and with out HACCP protocols using the procedures developed at this Center since 1979. The products were full fat soy flour, medium fat soy flour, soymilk, soy paneer(Tofu), soy bakery products (biscuits& bread), soy nuts, soy sprouts and protein isolates.
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Material s and Methods
The soybean variety JS 335 was obtained from the Institute Farm. It was cleaned thoroughly and made free from all the dirt, stubbles and other foreign matter.
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It was stored in airtight containers till further use. Different soy based foods were prepared following the methods developed at this center.
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FAO/WHO (2006) guidelines were used for the preparation of HACCP plans.
AOAC (1990) methods were used for analyzing various chemical constituents and APHA (1984) recommended methods were used for microbiological examination of the products.
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Full Fat S oy flo ur
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Table1.Product description 1. Product name 2. Important product characteristics of end product 3. How the product is to be used
Sealed polythene hermetically sealed containers.
4. Packaging
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Full Fat Soy flour Aw < 0.5;FFA < 1%; Total microbial counts < 50000/g Normally fortified with other cereals/millets/pulses at 1015% level in the preparation of traditional recipes.
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bags/ metal 94
5. Shelf-life
One month at normal retail shelf temperatures. 6. Where the product will be Retail, institutions and food service. Could be consumed sold as a health food. Required to ensure product 7. Labeling instructions safety. 8. Special distribution control
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No physical damage, excess humidity or temperature extremes.
95
Table 2.P roduct ingr edi ents and incoming mater ial Soybeans 1. Receiving P 5.Storing B P
Packaging material
Dry ingredients
2.Receiving P 6.Storing B C P 9.Inspecting B P
3. Receiving P 7. Storing B C P 10. Dumping
Water 4. In taking
8. Cleaning P 11. De hulling P 12. Soaking B C 14. Blanching B C 15.Drying B P C 16. Milling B P C
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17.Filling C P
13. Chlorinating
18.Weighing B 19.Closing/sealin gB 20.Inspecting B P Gandhi 21. Labeling B 22. Storing B
96
Table 3.Un add resse d Haz ards: Unaddressed hazard Soybeans could pesticide residues
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Identified methods of addressing the hazard contain Up stream (farm level) programs such as A: Training persons who apply pesticides. B: Purchasing registered pesticides for growers. C: Auditing growers application of pesticides and records there of. D: Requiring periodic pesticide residual analysis Gandhi 97 reports.
Table 4.HA CCP P lan Process step
Hazard description
Critical limits
Monitoring procedure
De hulling
Inefficient de hulling may cause the contamination of the product with the microorganis ms.
Less than 0.1%
On line check Line of the sample operator to adjust the clearance of the de huller drums.
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Deviation HACCP procedures records Operator log book
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Process step
Hazard description
Critical limits
Monitoring procedure
Deviation HACCP procedures records
Blanching/ cooking
In adequate heat treatment
Cook the splits as specified in the scheduled process (under pressure/o pen vessel boiling)
Check the quality of splits for urease test
Operator Operator should logbook. adjust the time and temperatur e as per the authorized contingenc y plan and to inform the QC.
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Process step
Hazard description
Critical limits
Monitoring procedure
Deviation HACCP procedures records
Drying (Sun/mech anical)
Improper drying
The moisture content should be less than 8%-10%.
Check the moisture content as per the guidelines.
If moisture Operators content is log book. greater the splits may be dried again and inform QC
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Process step
Hazard description
Critical limits
Monitoring procedure
Deviation procedures
HACCP records
Packaging and sealing
Over filling, improper gauge polythene and improper sealing
Max fill weight as specified in the scheduled process. Proper sealing leaving recommende d space.
On line check to reject over and under filled bags and improperly sealed bags.
Line operator to adjust the settings.
Operators log book and quality control report.
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Table 5.HAC CP for gener al activities: Stage Raw material harvest
Activity Liaison with the farmers for unit operations like harvesting, threshing and winnowing.
Control activity Specifications of grain quality are required. Rejection of under sized seeds.
Raw material transport
Transport in sacks to drying area
Correct sacking handling.
Raw material inspection
Sampling and inspection.
Preparation of seeds
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routine Correct sampling methods, training and inspection methods.
Cleaning, grading, dehulling, conditioning and blending. Gandhi
and
Training operators for equipment, preventing insect infestations, check for 102 moisture content.
Stage
Activity
Control activity
Milling and sieving, and Separation of Training in hygiene, dehulling components of seeds implementation of cleaning, and assessment of product quality. Packaging
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Filling in to containers Establish specifications and sealing. for labels and fill weights.
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Impl ementa ti on of HACCP
Receiving soybeans (CCP-1): Soybeans must come from approved dealers. At the time of its receipt it must be accompanied with its complete quality certificate and microbiological assessment reports. 08/20/09
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The
certificates should indicate the moisture content of the beans, degree of foreign materials and the microorganisms present (number of colonies), insects etc as compared to the upper approved standards of BIS/ISO. 08/20/09
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At
the time of receipt, visual control of soybeans must be carried out to find out the contaminants if any. Further more the proximate composition of the beans must be established with reference to its macro and micronutrients. Defective beans mean that the soy flour will be most likely unsafe for the consumption. 08/20/09
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Storage of soybeans in silos (CCP-4): The temperature (<20oC) and the relative humidity (<65%) during the storage must be low. They should be recorded at regular intervals. If any deviation from the safer limits, must be immediately rectified. When soybean is stored for a long period, microbiological analysis should be carried out.
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Receiving secondary materials (greasing, detergents, insecticides, pesticides and sacs) (CCP-2): These materials must be procured from the approved suppliers with quality certificates. These materials must be suitable for using them with food items. 08/20/09
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No
contamination must come from the packaging materials. If these materials do not comply with the standard specifications, must be returned to the suppliers and a new order should be placed with other suppliers. 08/20/09
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Storage of secondary materials (CCP-3): The temperature and relative humidity during storage must be below 20oC and 65% respectively. The place should be airconditioned. 08/20/09
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The
temperature and RH should be continuously recorded and corrective actions must be undertaken whenever any deviation occurs.
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Application of anti insect methods (CCP-5): Any chemicals used during storage along with the soybeans should comply with the safety legislations. The quantity should be with in the prescribed concentrations. 08/20/09
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Cleaning & grading of soybeans (CCP-6): All the physical contaminants should be removed. They should be graded. Only sound soybeans should be taken for processing. 08/20/09
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Removal of stones: The stones, metals and dust must be removed from the soybeans so that the final product will comply the quality standards as prescribed by BIS/ISO. Weighing: The soybeans are weighed and passed through a magnetic system so that the magnetic materials are removed. Gandhi 114
De hulling (CCP-7) Inefficient de hulling may cause the contamination of the product with the microorganisms. Less than 0.1% hulls are allowed. Hence an efficient dehulling should be used in order to prevent the contamination with the microorganisms. 08/20/09
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Blanching/cooking (CCP 8) In adequate heat treatment results in the poor quality of the product. Cook the splits as specified in the scheduled process (under pressure/open vessel boiling) to minimize the anti nutritional factors. Check the quality of splits for urease test. 08/20/09
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Drying (Sun/mechanical)(CCP 9)
Improper drying will result in the poor quality product. Hence proper drying methods are to be adopted for reducing the moisture content to the safe level( 8-10%). 08/20/09
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Milling (CCP-10): The grinding is done in a burr/hammer mill. The clearance between the burrs should be adjusted so that the flour must be having particle size <140 micrometers. Similarly with the hammer mill, the sieve below the grinding system must allow flour particles less than 140 micrometers. Gandhi 118
The
sieves should be of SS. The temperature during grinding should not rise too much, which affects the quality of the flour Normally a temperature rise of less than 5oC is desirable. So arrangements must be made to maintain the temperature while grinding. 08/20/09
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Packaging (CCP-11): During packaging the flour can possibly be contaminated with the microorganisms causing quality deterioration. Hermetic sealing and upright position of the packaging material can avoid this deterioration. 08/20/09
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There
should not be any migration of the low molecular weight substances from the packages. Further more contamination can take place from foreign materials like insects and rodents that accidentally happen to be packed with the flour. The personnel should comply with the GMPs. 08/20/09
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Storage of full fat flour (CCP-12): Both the temperature and relative humidity must be below 20oC and 65% respectively. They should be recorded and corrective actions must be taken when deviating. When the flour is stored for a long period, microbiological analysis is required. 08/20/09
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Metal detector (CCP-13): The
packed product passes through a metal detector. The product is then checked for its weight and placed in boxes (secondary packaging). The boxes are placed on the pallets and the packets are wrapped with film. 08/20/09
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Table 6.Q uality S tandar d E xpected
Composition: Protein: Fat: Crude Fiber: Ash: Moisture:
a minimum of 35% a minimum of 18% a maximum of 4% a maximum of 6.5% a maximum of 10%
Physical parameters: Granulation:
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90% minimum pass thru US sieve 200(0.074 mm)
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Microbiology: Total plate count: Total coli forms: Salmonella: E.coli: Staphylococcus: Yeast: Mold:
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20,000/g max 100/10g max Negative/100g Negative/100g 100/10g max 100/10g max 100/10g max.
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Protein solubility: TI: Urease activity: Available lysine:
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PDI 20-80% less than 75% of original. Nil Min 5.5g/6g N
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Sensory parameters: Color: Odor: Taste: Defects: Insect parts: Foreign material: Black specks: . 08/20/09
Creamy to yellow Less beany Nutty Total absence. Total absence Total absence
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Tab le 7 . Quality ass es sment of the Full Fat Soy Flo ur Quality standard expected Composition: Protein: a minimum of 35% Fat: a minimum of 18% Crude Fiber:a maximum of 4% Ash: a maximum of 6.5% Moisture: a maximum of 10% Physical parameters: Granulation: 90% minimum pass thru US sieve 200(0.074 mm) 08/20/09 .
With out HACCP
With HACCP
35%
40%
17%
20%
5.2% 5.4%
3.8% 6.3%
10%
8%
75%
95%
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Quality expected
standard With out HACCP
Microbiology: Total plate count: 20,000/g max Total coli forms: 100/10g max Salmonella: Negative/100g E.coli Negative/100g Staphylococcus: 100/10g max Yeast: 100/10g max Mold: 100/10g max. 08/20/09
50,000/g 120/10g 10/100g 15/100g 135/10g 123/10g 110/10g
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With HACCP
10,000/g Nil Nil Nil Nil Nil Nil 129
Quality expected
standard With out HACCP
Protein
solubility: 25% PDI 20-80% TI: less than 75% of original. 50% Urease activity: Nil Available 5.5g/6g N
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lysine:
With HACCP
75% 80%
Nil
Nil
4.2g/6gN
6.2g/6gN
Min
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Quality standard With out HACCP expected Sensory parameters: Color: Creamy to Yellow yellow Odor: Less beany Beany Taste: Nutty Nutty Defects: Insect parts: Total absence. Absent Foreign material: Total Absent absence.
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With HACCP
Creamy Less beany Nutty
Absent Absent
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Conclusion/Output: HACCP procedures were developed for making soy based foods (Full Fat Soy flour,Medium Fat Soy Flour,Soy Milk, Soy Paneer, Soy Bakery Products, Soy Nuts, Soy Sprouts and Soy Protein Isolates) with utmost quality and safe for use. A proactive approach was suggested to controlling the hazards through out the supply chain of soy based foods production. 08/20/09
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More flexibility in addressing identified hazards is given in the proposed HACCP program, which permits the soy food processors to select the appropriate and economical methods of control. Quality control managers are responsible for the design and maintenance of the suggested protocols with government agencies auditing compliance. 08/20/09
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Summary Table: Develop HACCP procedures for the production of different soy based foodsAccomplished. Test the developed procedures with a few soy-based foods such as full fat soy flour, soy milk, soy paneer (tofu), soy nuts and soy sprouts.-Evaluated.
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Document the developed procedures and final report writing- Documented. Gandhi
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Approximate expenditure incurred in the project (Rs): 3, 10,000.
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Recommendations: The HACCP procedures developed may be used for the production of different soy based foods with Good Manufacturing Processes and Good Food Hygiene Practices recommended by the Codex Alimanatarius Commission/FAO for maintaining the safety and quality of the products. 08/20/09
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Acknowledgments: Gratefully acknowledges the cooperation received from the Director, CIAE; Project Director and staff of SPU Center and every one of you in accomplishing the project and also during my entire service period(1979-2009) in general.
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Papers Published i. Gandhi, A.P. (2008) Development of HACCP procedure for the production of Full fat Soy Flour, International Food Research Journal 15(2), 141-154. ii. Gandhi, A.P. (2008). Production of Soy Nuts using the Hazard Analysis Critical Control Point (HACCP). Asian journal of Food and Agro industry, 1 (3),137-154. iii. Gandhi, A.P. (2009). Quality of Soybean and its food products-a review. International Food Research Journal,16(01),11-19. iv. Gandhi, A.P. (2009). Development of HACCP protocols for the production of soy milk, Accepted for publication in Asian journal of Food and Agro industry . Papers presented Gandhi, A.P (2008) Development of HACCP protocols for the production of soy milk, presented in the ISPUC, held at CIAE, Bhopal, December 1014,2008. Gandhi, A.P (2008) Use of Hazard Analysis Critical Control Point Principles in Quality Control of Soy Foods(Theme paper) presented in the ISPUC, held at CIAE, Bhopal, December 10-14,2008. 08/20/09
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THANK YOU
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A.P.Gandhi
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Project No:
583
Time spent:
25%
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Objectives i.To develop HACCP procedures for the production of different soy based foods. ii. To test the developed procedures with a few soy-based foods such as full fat soy flour, soy milk, soy paneer (tofu), soy nuts and soy sprouts. 08/20/09 Gandhi 3
iii. To document the developed procedures and final report writing.
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Technical program The drafting of procedures include identification of hazards and control measures, determination of critical control points, 08/20/09
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preparing
the decision tree, establishing the critical limits and marketing procedures,
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finding
the corrective action, responsibilities and verification procedures ,
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preparation
of HACCP chart documentation & record keeping for the soy based foods. 08/20/09
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Soy products: Flour (Full fat soy flour and medium fat soy flour). Soymilk and analogs (Soymilk (Plain) and, Soy paneer) ,Bakery products (Cookies and bread), Soy nuts,Soy sprouts, and Soy protein isolates . 08/20/09
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Date of Start: April 2007 Date of Completion: March 2009
The technical program was accomplished as approved.
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Various soy based foods like full fat soy flour, medium fat soy flour, soy milk, soy paneer(tofu), soy bakery products ,soy nuts were developed besides the protein isolates which find place in food formulations/pharmaceutical applications. These foods are to be produced with utmost safety.
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The availability of safe food improves the health of people and is a basic human right. Safe food contributes to health and productivity and provides an effective platform for development and poverty alleviation.
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The poor are the most susceptible to ill health. Trends in global food production, processing, distribution and preparation present new challenges to food safety.
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Food safety must be addressed along the entire food chain by measures based on sound scientific information at both national and international levels. Food safety is an essential public health issue.
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Food safety programs are increasingly focusing on a farm- to –table approach as an effective means of reducing food borne hazards. This holistic approach to the control of food related risks involves consideration of every step in the chain . 08/20/09 Gandhi 15
Now with the introduction of food quality and safety systems, HACCP has become synonymous with food safety. HACCP is a tool for process control to overcome the microbial hazards. The ultimate goal is improvement of public health.
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It is a world wide recognized systematic and preventive approach that addresses biological, chemical and physical hazards through anticipation and prevention rather than through end-product inspection and testing and thereby reducing the food borne illness.
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Prior to application of HACCP the production of soy based should be according to Codex General Principles of Food Hygiene, the appropriate Codex Codes of practice and appropriate food safety legislation.
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Good Agricultural Practices Primary production Environmental hygiene: Should not be carried out on in areas where the presence of potentially harmful substances would lead to an un acceptable level of such substances. 08/20/09
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Hygiene production of food sources: Producers should as far as practicable implement measures to Control contamination from air, soil, water, feed stuffs, fertilizers, pesticides, veterinary drugs or any other agent used in primary production. 08/20/09
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Control plant and animal health. Protect food sources from faecal and other contamination. Handling, storage and transport: Procedures should be in place to sort food and food ingredients to segregate material which is evidently unfit for human consumption.
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Dispose of any rejected material in a hygienic manner. Protect food and food ingredients from contamination by pests, chemical, physical or microbiological contaminants.
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Cleaning, maintenance and personnel hygiene at primary production: Appropriate facilities and procedures should be in place to ensure that Any necessary cleaning and maintenance is carried out effectively. An appropriate degree of personnel hygiene is maintained. 08/20/09
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Good Manufacturing Process Establishment of Design and facilities Location: Establishments They should be located away from Environmentally polluted areas and industrial activities which pose serious threat of contaminating the food. 08/20/09
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Areas subject to flooding unless sufficient safe guards are provided. Areas prone to infestation of pests. Areas where wastes, either solid or liquid can not be removed effectively.
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Equipment: Equipment should be located so that it Permits adequate maintenance and cleaning. Functions in accordance with its intended use. Facilitates good hygiene practices including monitoring. 08/20/09 Gandhi 26
Premises and rooms: Design and lay out Where appropriate the internal design and lay out of food establishments should permit good food hygiene practices including protection against cross contamination between and during operation of food stuffs. 08/20/09
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Internal structures and fittings: The surfaces of walls, partitions and floors should be made of impervious materials with no toxic effect in intended use. Walls and partitions should have a smooth surface up to a height appropriate to the operation. 08/20/09
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Floors should be constructed to allow adequate drainage and cleaning. Ceilings and overhead fixtures should be constructed and finished to minimize the build up of dirt and condensation and the shedding of particles.
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Window should be easy to clean, be constructed to minimize the build up of dirt and where necessary be fitted with removable and cleanable insect proof screens.Where necessary windows should be fixed.
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Doors should have smooth, non absorbent surfaces and be easy to clean and where necessary disinfect. Working surfaces that come into direct contact with food should be in sound condition, durable and easy to clean.
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Equipment: They can be adequately cleaned, disinfected and maintained to avoid the contamination of food. Equipment and containers should be made of materials with no toxic effect in intended use. 08/20/09
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Where
necessary equipment should be durable and movable or capable of being disassembled to allow for maintenance, cleaning, disinfections, monitoring.
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Food control and monitoring equipment: The equipment used to cook, heat treat, cool, store or freeze should be designed to achieve the required food temperatures as rapidly as necessary in the interests of food safety and suitability and maintain them effectively. 08/20/09
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Containers for waste and inedible substances: Containers for waste, by products and inedible or dangerous substances should be specifically identifiable, suitably constructed and where appropriate made of impervious material. 08/20/09
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Containers
used to hold dangerous substances should be identified and where appropriate, be lockable to prevent malicious or accidental contamination of food.
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Personnel hygiene facilities and toilets: Where appropriate adequate means of hygienically washing and drying hands, including wash basins and a supply of hot and cold water. Lavatories of appropriate design. Adequate changing facilities for personnel. 08/20/09
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Temperature Control: Adequate facilities should be available for heating, cooling, refrigerating and freezing food, for storing refrigerated or frozen foods, monitoring the food temperatures and when necessary controlling the ambient temperatures to ensure the safety and suitability of food. 08/20/09
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Air Quality and ventilation: Adequate means of natural and mechanical ventilation should be provided to Control ambient temperatures. Minimize the air borne contamination of food. Control odors. Control humidity where necessary. 08/20/09
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Facilities: Water supply An adequate supply of potable water with appropriate facilities for its storage, distribution and temperature control should be available where necessary to ensure the safety and suitability of food. 08/20/09
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Potable water should be as specified in WHO Guidelines. Non potable water shall have a separate system and shall be identified.
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Drainage and waste disposal: Adequate drainage and waste disposal systems and facilities should be provided.
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Cleaning: Adequate facilities, suitably designated should be provided for cleaning the food utensils and equipment. Such facilities should have an adequate supply of hot and cold potable water where appropriate. 08/20/09
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Control of operation Adequate time, temperature or humidity controls. Food grade packaging. Potable water supplies. Maintenance of equipment. 08/20/09
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Maintenance and Sanitation Adequate level of maintenance of an establishment as well as efficient practices for cleaning, waste management and pest control.
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Personal Hygiene Health Status: People known or suspected to be suffering from or to be a carrier of a disease or illness likely to be transmitted through food should not be allowed. 08/20/09
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Illness and injuries:
Conditions which should be reported include jaundice, diarrhea,vomiting, fever, sore throat with fever, visibly infected skin lesions and discharges from the ear , eye or nose.
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Personnel cleanliness: They should wear suitable protective clothing, head covering and footwear.Cuts and wounds where personnel are permitted to continue working should be covered by suitable water proof dressings. 08/20/09
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Personnel should always wash their hands -at the start of food handling activities. -Immediately after using the toilet. -After handling raw food or any contaminated material.
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Personal Behavior: People engaged in food handling activities should refrain from behavior which could result in contamination of food like smoking, spitting, chewing or eating and sneezing or coughing over unprotected food. 08/20/09
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Visitors: Visitors to food manufacturing, processing or handling areas should where appropriate wear protective clothing and adhere to other personal hygiene.
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Transportation Method of transportation should be such that measures are taken to prevent any contamination or deterioration of the product. Controlled environments like chilled, frozen or stored under specific humidity levels. 08/20/09
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Containers need to be maintained in good condition and be easy to clean. Designed specifically for food use only.
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Training All food handlers should be trained in personal hygiene, and should be supervised by the trained supervisors.
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Product information and consumer awareness: The product should be accompanied by adequate information. All batches should be identified by a batch or lot number to allow trace ability of the commodity if required. 08/20/09
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Management commitment is necessary for implementation of an effective HACCP system.
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No relevant published data is available on the usage of HACCP in the production of soy-based foods globally too.
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Hence efforts were made to draft the HACCP procedures for the production of different soy based foods.
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Food safety in today’s’ world is paramount. HACCP programmes go a long way to ensuring this food safety. We rely on food to nourish and sustain us. We want food that is appealing and pleasurable to eat.
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We need food that will not cause us injury or illness or severe cases cause death. There are members of our community- the young, the not so young, the immunocompromised and those who are susceptible to allergies and intolerances that rely on us in the food industry to supply them with safe food.
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May our efforts be not in vain as we meet this responsibility each day?
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PR INC IPLE S OF TH E HAC CP SYS TEM
PRINCIPLE 1 Conduct a hazard analysis. PRINCIPLE 2 Determine the Critical Control Points (CCPs). PRINCIPLE 3 Establish critical limit(s). 08/20/09
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PR IN CIPL ES OF T HE H ACCP SY STEM
PRINCIPLE 4
Establish a system to monitor control of the CCP. PRINCIPLE 5
Establish the corrective action to be taken when monitoring indicates that a particular CCP is not under control. 08/20/09
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PRINCIPLE 6
Establish procedures for verification to confirm that the HACCP system is working effectively. PRINCIPLE 7
Establish documentation concerning all procedures and records appropriate to these principles and their application. 08/20/09
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APP LI CA TI ON
1. Assemble HACCP team
The food operation should assure that the appropriate product specific knowledge and expertise is available for the development of an effective HACCP plan.
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Optimally, this may be accomplished by assembling a multidisciplinary team. Where such expertise is not available on site, expert advice should be obtained from other sources. 08/20/09
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The scope of the HACCP plan should be identified. The scope should describe which segment of the food chain is involved and the general classes of hazards to be addressed (e.g. does it cover all classes of hazards or only selected classes).
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2. Describe product
A full description of the product should be drawn up, including relevant safety information such as: composition, physical/chemical structure (including Aw, pH, etc.), microcidal/static treatments (heat-treatment, freezing, brining, smoking, etc.), packaging, durability and storage conditions and method of distribution. 08/20/09
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3. Identify intended use
The intended use should be based on the expected uses of the product by the end user or consumer. In specific cases, vulnerable groups of the population, e.g. institutional feeding, may have to be considered. 08/20/09
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4. Construct flow diagram
The HACCP team should construct the flow diagram. The flow diagram should cover all steps in the operation. When applying HACCP to a given operation, consideration should be given to steps preceding and following the specified operation. 08/20/09
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5. On-site confirmation of flow diagram
The HACCP team should confirm the processing operation against the flow diagram during all stages and hours of operation and amend the flow diagram where appropriate.
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6. List all potential hazards associated with
each step, conduct a hazard analysis, and consider any measures to control identified hazards. The HACCP team should list all of the hazards that may be reasonably expected to occur at each step from primary production, processing, manufacture, and distribution until the point of consumption. 08/20/09
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The HACCP team should next conduct a hazard analysis to identify for the HACCP plan, which hazards are of such a nature that their elimination or reduction to acceptable levels is essential to the production of a safe food. 08/20/09
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7. Determine Critical Control Points There may be more than one CCP at which control is applied to address the same hazard. The determination of a CCP in the HACCP system can be facilitated by the application of a decision tree which indicates a logic reasoning approach. 08/20/09
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Application of a decision tree should be flexible, given whether the operation is for production, slaughter, processing, storage, distribution or other. It should be used for guidance when determining CCPs. 08/20/09
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8. Establish critical limits for each CCP . Critical limits must be specified and validated if possible for each Critical Control Point. In some cases more than one critical limit will be elaborated at a particular step. 08/20/09
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Criteria often used include measurements of temperature, time, moisture level, pH, Aw, available chlorine, and sensory parameters such as visual appearance and texture.
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9. Establish a monitoring system for
each CCP. Monitoring is the scheduled measurement or observation of a CCP relative to its critical limits. The monitoring procedures must be able to detect loss of control at the CCP. 08/20/09
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Further, monitoring should ideally provide this information in time to make adjustments to ensure control of the process to prevent violating the critical limits. Where possible, process adjustments should be made when monitoring results indicate a trend towards loss of control at a CCP.
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10. Establish corrective actions . Specific corrective actions must be developed for each CCP in the HACCP system in order to deal with deviations when they occur.
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The actions must ensure that the CCP has been brought under control. Actions taken must also include proper disposition of the affected product. Deviation and product disposition procedures must be documented in the HACCP record keeping.
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11. Establish verification procedures .
Verification and auditing methods, procedures and tests, including random sampling and analysis, can be used to determine if the HACCP system is working correctly. The frequency of verification should be sufficient to confirm that the HACCP system is working effectively.
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12. Establish Documentation and Record Keeping . Efficient and accurate record keeping is essential to the application of a HACCP system. HACCP procedures should be documented. Documentation and record keeping should be appropriate to the nature and size of the operation. 08/20/09
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TRA INI NG
Training of personnel in industry, government and academia in HACCP principles and applications, and increasing awareness of consumers are essential elements for the effective implementation of HACCP.
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As an aid in developing specific training to support a HACCP plan, working instructions and procedures should be developed which define the tasks of the operating personnel to be stationed at each Critical Control Point. Cooperation between primary producer, industry, trade groups, consumer organizations, and responsible authorities are of vital importance .
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Applicat ion of HAC CP in S oy foods
Various soy-based foods were prepared with and with out HACCP protocols using the procedures developed at this Center since 1979. The products were full fat soy flour, medium fat soy flour, soymilk, soy paneer(Tofu), soy bakery products (biscuits& bread), soy nuts, soy sprouts and protein isolates.
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Material s and Methods
The soybean variety JS 335 was obtained from the Institute Farm. It was cleaned thoroughly and made free from all the dirt, stubbles and other foreign matter.
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It was stored in airtight containers till further use. Different soy based foods were prepared following the methods developed at this center.
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FAO/WHO (2006) guidelines were used for the preparation of HACCP plans.
AOAC (1990) methods were used for analyzing various chemical constituents and APHA (1984) recommended methods were used for microbiological examination of the products.
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Full Fat S oy flo ur
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Table1.Product description 1. Product name 2. Important product characteristics of end product 3. How the product is to be used
Sealed polythene hermetically sealed containers.
4. Packaging
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Full Fat Soy flour Aw < 0.5;FFA < 1%; Total microbial counts < 50000/g Normally fortified with other cereals/millets/pulses at 1015% level in the preparation of traditional recipes.
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bags/ metal 94
5. Shelf-life
One month at normal retail shelf temperatures. 6. Where the product will be Retail, institutions and food service. Could be consumed sold as a health food. Required to ensure product 7. Labeling instructions safety. 8. Special distribution control
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No physical damage, excess humidity or temperature extremes.
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Table 2.P roduct ingr edi ents and incoming mater ial Soybeans 1. Receiving P 5.Storing B P
Packaging material
Dry ingredients
2.Receiving P 6.Storing B C P 9.Inspecting B P
3. Receiving P 7. Storing B C P 10. Dumping
Water 4. In taking
8. Cleaning P 11. De hulling P 12. Soaking B C 14. Blanching B C 15.Drying B P C 16. Milling B P C
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17.Filling C P
13. Chlorinating
18.Weighing B 19.Closing/sealin gB 20.Inspecting B P Gandhi 21. Labeling B 22. Storing B
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Table 3.Un add resse d Haz ards: Unaddressed hazard Soybeans could pesticide residues
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Identified methods of addressing the hazard contain Up stream (farm level) programs such as A: Training persons who apply pesticides. B: Purchasing registered pesticides for growers. C: Auditing growers application of pesticides and records there of. D: Requiring periodic pesticide residual analysis Gandhi 97 reports.
Table 4.HA CCP P lan Process step
Hazard description
Critical limits
Monitoring procedure
De hulling
Inefficient de hulling may cause the contamination of the product with the microorganis ms.
Less than 0.1%
On line check Line of the sample operator to adjust the clearance of the de huller drums.
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Deviation HACCP procedures records Operator log book
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Process step
Hazard description
Critical limits
Monitoring procedure
Deviation HACCP procedures records
Blanching/ cooking
In adequate heat treatment
Cook the splits as specified in the scheduled process (under pressure/o pen vessel boiling)
Check the quality of splits for urease test
Operator Operator should logbook. adjust the time and temperatur e as per the authorized contingenc y plan and to inform the QC.
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Process step
Hazard description
Critical limits
Monitoring procedure
Deviation HACCP procedures records
Drying (Sun/mech anical)
Improper drying
The moisture content should be less than 8%-10%.
Check the moisture content as per the guidelines.
If moisture Operators content is log book. greater the splits may be dried again and inform QC
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Process step
Hazard description
Critical limits
Monitoring procedure
Deviation procedures
HACCP records
Packaging and sealing
Over filling, improper gauge polythene and improper sealing
Max fill weight as specified in the scheduled process. Proper sealing leaving recommende d space.
On line check to reject over and under filled bags and improperly sealed bags.
Line operator to adjust the settings.
Operators log book and quality control report.
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Table 5.HAC CP for gener al activities: Stage Raw material harvest
Activity Liaison with the farmers for unit operations like harvesting, threshing and winnowing.
Control activity Specifications of grain quality are required. Rejection of under sized seeds.
Raw material transport
Transport in sacks to drying area
Correct sacking handling.
Raw material inspection
Sampling and inspection.
Preparation of seeds
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routine Correct sampling methods, training and inspection methods.
Cleaning, grading, dehulling, conditioning and blending. Gandhi
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Training operators for equipment, preventing insect infestations, check for 102 moisture content.
Stage
Activity
Control activity
Milling and sieving, and Separation of Training in hygiene, dehulling components of seeds implementation of cleaning, and assessment of product quality. Packaging
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Filling in to containers Establish specifications and sealing. for labels and fill weights.
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Impl ementa ti on of HACCP
Receiving soybeans (CCP-1): Soybeans must come from approved dealers. At the time of its receipt it must be accompanied with its complete quality certificate and microbiological assessment reports. 08/20/09
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The
certificates should indicate the moisture content of the beans, degree of foreign materials and the microorganisms present (number of colonies), insects etc as compared to the upper approved standards of BIS/ISO. 08/20/09
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At
the time of receipt, visual control of soybeans must be carried out to find out the contaminants if any. Further more the proximate composition of the beans must be established with reference to its macro and micronutrients. Defective beans mean that the soy flour will be most likely unsafe for the consumption. 08/20/09
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Storage of soybeans in silos (CCP-4): The temperature (<20oC) and the relative humidity (<65%) during the storage must be low. They should be recorded at regular intervals. If any deviation from the safer limits, must be immediately rectified. When soybean is stored for a long period, microbiological analysis should be carried out.
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Receiving secondary materials (greasing, detergents, insecticides, pesticides and sacs) (CCP-2): These materials must be procured from the approved suppliers with quality certificates. These materials must be suitable for using them with food items. 08/20/09
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No
contamination must come from the packaging materials. If these materials do not comply with the standard specifications, must be returned to the suppliers and a new order should be placed with other suppliers. 08/20/09
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Storage of secondary materials (CCP-3): The temperature and relative humidity during storage must be below 20oC and 65% respectively. The place should be airconditioned. 08/20/09
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The
temperature and RH should be continuously recorded and corrective actions must be undertaken whenever any deviation occurs.
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Application of anti insect methods (CCP-5): Any chemicals used during storage along with the soybeans should comply with the safety legislations. The quantity should be with in the prescribed concentrations. 08/20/09
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Cleaning & grading of soybeans (CCP-6): All the physical contaminants should be removed. They should be graded. Only sound soybeans should be taken for processing. 08/20/09
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Removal of stones: The stones, metals and dust must be removed from the soybeans so that the final product will comply the quality standards as prescribed by BIS/ISO. Weighing: The soybeans are weighed and passed through a magnetic system so that the magnetic materials are removed. Gandhi 114
De hulling (CCP-7) Inefficient de hulling may cause the contamination of the product with the microorganisms. Less than 0.1% hulls are allowed. Hence an efficient dehulling should be used in order to prevent the contamination with the microorganisms. 08/20/09
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Blanching/cooking (CCP 8) In adequate heat treatment results in the poor quality of the product. Cook the splits as specified in the scheduled process (under pressure/open vessel boiling) to minimize the anti nutritional factors. Check the quality of splits for urease test. 08/20/09
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Drying (Sun/mechanical)(CCP 9)
Improper drying will result in the poor quality product. Hence proper drying methods are to be adopted for reducing the moisture content to the safe level( 8-10%). 08/20/09
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Milling (CCP-10): The grinding is done in a burr/hammer mill. The clearance between the burrs should be adjusted so that the flour must be having particle size <140 micrometers. Similarly with the hammer mill, the sieve below the grinding system must allow flour particles less than 140 micrometers. Gandhi 118
The
sieves should be of SS. The temperature during grinding should not rise too much, which affects the quality of the flour Normally a temperature rise of less than 5oC is desirable. So arrangements must be made to maintain the temperature while grinding. 08/20/09
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Packaging (CCP-11): During packaging the flour can possibly be contaminated with the microorganisms causing quality deterioration. Hermetic sealing and upright position of the packaging material can avoid this deterioration. 08/20/09
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There
should not be any migration of the low molecular weight substances from the packages. Further more contamination can take place from foreign materials like insects and rodents that accidentally happen to be packed with the flour. The personnel should comply with the GMPs. 08/20/09
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Storage of full fat flour (CCP-12): Both the temperature and relative humidity must be below 20oC and 65% respectively. They should be recorded and corrective actions must be taken when deviating. When the flour is stored for a long period, microbiological analysis is required. 08/20/09
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Metal detector (CCP-13): The
packed product passes through a metal detector. The product is then checked for its weight and placed in boxes (secondary packaging). The boxes are placed on the pallets and the packets are wrapped with film. 08/20/09
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Table 6.Q uality S tandar d E xpected
Composition: Protein: Fat: Crude Fiber: Ash: Moisture:
a minimum of 35% a minimum of 18% a maximum of 4% a maximum of 6.5% a maximum of 10%
Physical parameters: Granulation:
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90% minimum pass thru US sieve 200(0.074 mm)
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Microbiology: Total plate count: Total coli forms: Salmonella: E.coli: Staphylococcus: Yeast: Mold:
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20,000/g max 100/10g max Negative/100g Negative/100g 100/10g max 100/10g max 100/10g max.
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Protein solubility: TI: Urease activity: Available lysine:
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PDI 20-80% less than 75% of original. Nil Min 5.5g/6g N
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Sensory parameters: Color: Odor: Taste: Defects: Insect parts: Foreign material: Black specks: . 08/20/09
Creamy to yellow Less beany Nutty Total absence. Total absence Total absence
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Tab le 7 . Quality ass es sment of the Full Fat Soy Flo ur Quality standard expected Composition: Protein: a minimum of 35% Fat: a minimum of 18% Crude Fiber:a maximum of 4% Ash: a maximum of 6.5% Moisture: a maximum of 10% Physical parameters: Granulation: 90% minimum pass thru US sieve 200(0.074 mm) 08/20/09 .
With out HACCP
With HACCP
35%
40%
17%
20%
5.2% 5.4%
3.8% 6.3%
10%
8%
75%
95%
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Quality expected
standard With out HACCP
Microbiology: Total plate count: 20,000/g max Total coli forms: 100/10g max Salmonella: Negative/100g E.coli Negative/100g Staphylococcus: 100/10g max Yeast: 100/10g max Mold: 100/10g max. 08/20/09
50,000/g 120/10g 10/100g 15/100g 135/10g 123/10g 110/10g
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With HACCP
10,000/g Nil Nil Nil Nil Nil Nil 129
Quality expected
standard With out HACCP
Protein
solubility: 25% PDI 20-80% TI: less than 75% of original. 50% Urease activity: Nil Available 5.5g/6g N
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lysine:
With HACCP
75% 80%
Nil
Nil
4.2g/6gN
6.2g/6gN
Min
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Quality standard With out HACCP expected Sensory parameters: Color: Creamy to Yellow yellow Odor: Less beany Beany Taste: Nutty Nutty Defects: Insect parts: Total absence. Absent Foreign material: Total Absent absence.
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With HACCP
Creamy Less beany Nutty
Absent Absent
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Conclusion/Output: HACCP procedures were developed for making soy based foods (Full Fat Soy flour,Medium Fat Soy Flour,Soy Milk, Soy Paneer, Soy Bakery Products, Soy Nuts, Soy Sprouts and Soy Protein Isolates) with utmost quality and safe for use. A proactive approach was suggested to controlling the hazards through out the supply chain of soy based foods production. 08/20/09
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More flexibility in addressing identified hazards is given in the proposed HACCP program, which permits the soy food processors to select the appropriate and economical methods of control. Quality control managers are responsible for the design and maintenance of the suggested protocols with government agencies auditing compliance. 08/20/09
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Summary Table: Develop HACCP procedures for the production of different soy based foodsAccomplished. Test the developed procedures with a few soy-based foods such as full fat soy flour, soy milk, soy paneer (tofu), soy nuts and soy sprouts.-Evaluated.
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Document the developed procedures and final report writing- Documented. Gandhi
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Approximate expenditure incurred in the project (Rs): 3, 10,000.
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Recommendations: The HACCP procedures developed may be used for the production of different soy based foods with Good Manufacturing Processes and Good Food Hygiene Practices recommended by the Codex Alimanatarius Commission/FAO for maintaining the safety and quality of the products. 08/20/09
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Acknowledgments: Gratefully acknowledges the cooperation received from the Director, CIAE; Project Director and staff of SPU Center and every one of you in accomplishing the project and also during my entire service period(1979-2009) in general.
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Papers Published i. Gandhi, A.P. (2008) Development of HACCP procedure for the production of Full fat Soy Flour, International Food Research Journal 15(2), 141-154. ii. Gandhi, A.P. (2008). Production of Soy Nuts using the Hazard Analysis Critical Control Point (HACCP). Asian journal of Food and Agro industry, 1 (3),137-154. iii. Gandhi, A.P. (2009). Quality of Soybean and its food products-a review. International Food Research Journal,16(01),11-19. iv. Gandhi, A.P. (2009). Development of HACCP protocols for the production of soy milk, Accepted for publication in Asian journal of Food and Agro industry . Papers presented Gandhi, A.P (2008) Development of HACCP protocols for the production of soy milk, presented in the ISPUC, held at CIAE, Bhopal, December 1014,2008. Gandhi, A.P (2008) Use of Hazard Analysis Critical Control Point Principles in Quality Control of Soy Foods(Theme paper) presented in the ISPUC, held at CIAE, Bhopal, December 10-14,2008. 08/20/09
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THANK YOU
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