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HACCP plan proposal for a typical Brazilian peanut processing company
Abstract
Peanuts are likely to be infested by fungi with consequent contamination by aflatoxin in post-harvest industries. A hazard analysis critical control point (HACCP) plan is proposed for a typical Brazilian post-harvest industry from raw in-shell reception to the unpeeled peanuts transportation. Codex Alimentarius Commission guidelines were followed, with four critical control points (CCP) for aflatoxin being identified. The process steps with highest probability of aflatoxin occurrence (risk) are the in-shell reception, the dried in-shell storage, and the unpeeled kernel storage. During the storage steps there is a lack of control of air moisture and temperature. Therefore, there is no option but to keep rigid monitoring and control over each CCP, and detour lots with high aflatoxin levels to either oil or seed production. Attempts to correlate the aflatoxin levels with the rainfall showed an irregular trend of the toxin level.
... Aflatoxins are natural contaminants with important toxic effects for human and animal health that are produced mainly by the aflatoxigenic strains of Aspergillus flavus and A. parasiticus. Aflatoxins represent a public health problem because they remain partially stable even during industrial processes that foods are subjected to (EFSA, 2013;Milani and Maleki, 2014). The International Agency of Research on Cancer (IARC) classified aflatoxins as carcinogens agents in Group 1 (carcinogenic to humans) (IARC, 2002) and the aflatoxin B 1 has the highest carcinogenic potential among the known mycotoxins (EFSA, 2013). ...
... Aflatoxins represent a public health problem because they remain partially stable even during industrial processes that foods are subjected to (EFSA, 2013;Milani and Maleki, 2014). The International Agency of Research on Cancer (IARC) classified aflatoxins as carcinogens agents in Group 1 (carcinogenic to humans) (IARC, 2002) and the aflatoxin B 1 has the highest carcinogenic potential among the known mycotoxins (EFSA, 2013). The contamination of peanuts produced in Brazil is a concern because the climatic conditions prevailing in the country, allied to the traditional practices of harvest, drying and storage, allow the infestation of the kernels by Aspergillus spp and the consequent production of aflatoxins (Gorayeb et al., 2009;Souza et al., 2014). ...
... The International Agency of Research on Cancer (IARC) classified aflatoxins as carcinogens agents in Group 1 (carcinogenic to humans) (IARC, 2002) and the aflatoxin B 1 has the highest carcinogenic potential among the known mycotoxins (EFSA, 2013). The contamination of peanuts produced in Brazil is a concern because the climatic conditions prevailing in the country, allied to the traditional practices of harvest, drying and storage, allow the infestation of the kernels by Aspergillus spp and the consequent production of aflatoxins (Gorayeb et al., 2009;Souza et al., 2014). ...
Paçoca is a very popular product of indigenous origin that is widely consumed by children, especially during the annual folkloric celebrations in June and July in Brazil. One of the main risks of this peanut candy is contamination by aflatoxins. Aflatoxins are natural contaminants produced mainly by the aflatoxigenic strains of Aspergillus flavus and Aspergillus parasiticus, and have important toxic effects for humans, such as, acute aflatoxicosis and risk of cancer development. This work aimed to determine the levels of aflatoxins in 36 different brands of paçoca samples marketed in Rio de Janeiro, Brazil, during the period of folkloric celebrations in
2012, and to estimate the aflatoxins intake by children and adolescents using a Food Frequency. Questionnaire applied to 157 individuals. The aflatoxins were quantified by High Performance Liquid Chromatography with Fluorescence Detection in 72 paçoca samples (100%). Twentyseven samples (37.4%) were positive for aflatoxins and ten (13.8%) showed aflatoxins levels higher than the limit established by Brazilian legislation for peanut products (20 µg/kg). The overall average corresponded to 4.9 µg/kg and the highest value found was 39.6 µg/kg. The Probable Daily Intake (PDI) of aflatoxins through the consumption of paçoca corresponded to 1.37 ng/kg body weight (b.w.). Children aged from 8 to 11 were the most exposed to these mycotoxins, which may pose a significant risk to their health. This is the first report to be made showing levels of aflatoxinas in a peanut product marketed in Rio de Janeiro, Brazil.
... Hazard analysis critical control point system (HA-CCPS) is a protocol designed to identify, evaluate and control hazards to the consumers' health and to guarantee food safety. It was originally developed 40 years ago through a collaboration between NASA, the Pillsbury company and the US army laboratories that aimed to produce safe food for US astronauts (FAO, 2001;Aldred et al., 2004;Gorayeb et al., 2009). The HACCP system is intended to address the hazards for which elimination or reduction to acceptable levels is essential to the production of safe food (FAO, 2001). ...
... This result indicates that roasting and preparation of groundnutbased food eliminated contaminating mycoflora. The A w from the prime matter stage up to the final product was below 0.8 (0.390-0.498 - Table 2), which according to Gorayeb et al. (2009), is the maximum limit for the production of aflatoxins by A. flavus. Therefore, even though there was aflatoxin-producing Aspergillus in CCPPs 1 and 2 samples, there was no water present to allow the development of fungus and production of aflatoxin. ...
... This variation to the mixture may have been caused by such ingredients as sugar, sodium bicarbonate, sorbic acid, manioc flour, salt and maize glucose syrup. According to the Codex Alimentarius Commission (CAC, 1995) and Gorayeb et al. (2009), a moisture content lower than 10% may ensure that prime matter does not develop toxigenic fungi and produce mycotoxins. In the current study, mean moisture content of the samples received by the industry was 6.2%. ...
This study was conducted to identify and assess the critical control points (CCPs) in groundnut-based food production in southern Brazil in order to reduce or eliminate aflatoxin contamination. This methodology has been suggested by the Food and Agriculture Organization (FAO) of the United Nations. Reception of prime matter, groundnut storage, roasting and thermal treatment were the main CCPs identified. Critical factors were the determination of aflatoxin, moisture content and water activity (A w) during groundnut reception and storage, control of temperature, roasting time and thermal treatment in the groundnut-based food manufacturing. The critical limit for moisture was 8.2% and 0.6 was established for A w . In Brazil, the limit for aflatoxins B 1 , B 2 , G 1 and G 2 has been established at 20 ppb. Temperatures of 180 °C ⁄ 1 h and 80 °C ⁄ 40 min were established for roasting and thermal treatment stages of groundnut-based food, respectively.
... isolated from sea salt and underground rock salt with pigmentation had a high salt tolerance at 1.5%-5.0% NaCl Juneja 2000, Frazier andWesthoff 2013). Halobacterium sp. was also found to grow in high salt concentrations at 15%-20% NaCl (Oren et al. 1992), and H. salinarum has been associated with high-salt (4.4-5.1 M NaCl) fermented fish products, such as the Thai fish sauce, nam-pla (Thongthai et al. 1992). ...
Aims:
To develop a model HACCP plan related to the microbiological hazards for the traditional fermented crab.
Methods and results:
The microbiological and chemical characteristics of commercial products were surveyed. Microbiological hazard analysis was performed for raw materials and during processing. Critical control points (CCPs) were determined using a decision tree, with CCP1 as saturated salt preparation and CCP2 as fermentation. The critical limit (CL) of CCP1 was at 100°C for 20 min applied to brining and of CCP2 was at 25% NaCl for the brine applied to fermented crab. Isolated microbial hazards and type strains were used for the validation of the CLs. Monitoring and verification of the proposed HACCP plan were carried out, and an effective HACCP plan was established.
Conclusions:
The HACCP plan promoted the safe consumption of fermented crab with the provided CCPs at the saturated salt preparation and fermentation steps. The effective CLs to ensure microbiological hazards as safe at the CCPs provide the best support for an effective plan. The hazards were reduced significantly after the HACCP plan had been applied.
... armazenamento, exposição à venda, entre outras etapas que representem risco de contaminação que se relacione com a segurança do produto, ou seja, abrange funções desde a produção primária, as indústrias, os consumidores, os transportadores, os inspetores/fiscalizadores, os importadores/exportadores e os fornecedores de produtos e serviços de qualquer natureza que influenciem a segurança do alimento. Conforme descrito porForsythe (2013), o Sistema APPCC é baseado em sete princípios: SegundoGorayeb et al. (2009), apesar da metodologia de APPCC ser muito bem estruturada, ela depende de uma análise subjetiva da equipe, de suas habilidades e conhecimentos, embasadas em experiências anteriores.3.8 CODEX ALIMENTARIUSO Codex Alimentarius é um conjunto de normas técnicas que estabelece padrões de qualidade sanitária e de segurança para os alimentos comercializados internacionalmente, visando proteger a saúde dos consumidores e assegurar práticas equitativas no comércio internacional de alimentos, tendo em vista o contexto de mundialização dinâmico e evolutivo, em que intoxicações alimentares se propagam mais facilmente e mais rapidamente. ...
O presente artigo tem como finalidade analisar e mapear, com a modelagem BPMN, o processo produtivo de uma empresa produtora de açaí localizada no Baixo Tocantins, investigar seus perigos (contaminação microbiológica) e a elaboração de uma proposta de gestão de processos com ênfase no gerenciamento e monitoração dos Pontos Críticos de Controle (PCC) através da metodologia APPCC e também de um plano estruturado com a ferramenta 5W1H. Para isso, foi realizado um estudo teórico envolvendo os conteúdos citados, uma pesquisa de campo informal objetivando compreender os processos, logo em seguida foi realizada a análise dos dados obtidos que geraram informações que puderam ser manipuladas através dos 7 princípios da metodologia utilizada.
... The pecan and walnut industries employ many interventions to reduce the likelihood of the production of contaminated food products. Good Agricultural Practices (G.A.P.s) are utilized to ensure that products produced meet both the quality and safety standards [123]. These practices exist to minimize situations that allow for bacterial survival and growth throughout the production of tree nuts. ...
... Dalam pelaksanaan GMP, antara halangan terbesar kepada pengusaha makanan ialah komitmen untuk mengubahsuai premis mereka (Fotopoulos et al. 2009;Gorayeb et al. 2009;Hielm et al. 2006;Mutlu et al. 2003;Taylor 2001, N.Z. Noor Hasnan et. ...
Pematuhan terhadap keperluan premis adalah salah satu syarat di dalam standard dan pensijilan Halal Malaysia. Selain daripada penggunaan MS1500, antara standard yang melengkapkan pensijilan Halal ialah MS 1514 yang menggariskan keperluan Amalan Pengilangan yang Baik (GMP). Satu kajian telah dijalankan untuk mengenalpasti kefahaman pengusaha kecil dan sederhana (PKS) industri makanan dan perunding keselamatan makanan di sekitar Lembah Kelang, Malaysia dalam pemilihan bahan struktur dalaman premis untuk memenuhi keperluan peruntukan Klausa 4.0 MS 1514 Rekabentuk dan Kemudahan. Kajian yang dijalankan adalah berbentuk soal selidik melibatkan seramai 42 responden yang terdiri daripada 21 PKS dan 21 perunding keselamatan makanan. Hasil kajian menunjukkan terdapat jurang pengetahuan (p<0.05) antara perunding dan PKS bagi pemilihan bahan struktur dalaman premis iaitu bagi pemilihan bahan keluli tahan karat dan resin epoksi sebagai kemasan lantai dikawasan pemprosesan basah dan kawasan memasak / panas, pemilihan jubin kuari sebagai kemasan lantai di kawasan sejuk / sejuk beku dan kemasan dinding di kawasan sejuk / sejuk beku, kawasan kering dan di kawasan memasak / panas, pemilihan keluli tahan karat sebagai kemasan lantai di kawasan kering dan kemasan siling di kawasan pemprosesan basah, pemilihan plaster bercat sebagai siling di kawasan sejuk / sejuk beku dan bahan-bahan lain di kawasan memasak / panas.
... Aflatoxin concentration increases during storage mostly due to poor storage facilities, and high humidity and temperature (Pitt et al., 2013). The economic cost of controlling temperature and humidity in processing plants to inhibit the growth of Aspergillus fungi and aflatoxin accumulation are often not affordable for farmers (Gorayeb et al., 2009); farmers are even more unlikely to spend this money on storage facilities. Meanwhile, ordinary containers, such as silos, bags, and tarps are unable to effectively contain further contamination. ...
Aflatoxin is a fungal secondary metabolite with high toxicity that is capable of contaminating various types of food crops. It has been identified as a Group 1 human carcinogen by the International Agency for Research on Cancer. Chronic aflatoxin exposure has caused worldwide concern as a matter of public food safety. Peanuts and peanut products are the major sources of aflatoxin exposure. Therefore, some reduction interventions have been developed to minimize contamination throughout the peanut production chain. The purpose of this study is to estimate the efficacy of interventions in reducing the health impact of hepatocellular carcinoma caused by aflatoxin contamination in peanuts. The estimated total Disability-Adjusted Life Years (DALYs) were calculated using FDA-iRISK software. Six aflatoxin reduction strategies were evaluated, including good agricultural practice (GAP), biocontrol, Purdue Improved Crop Storage packaging, basic processing, ozonolysis, and ultraviolet irradiation. The results indicated that basic processing could prevent huge public health loss of 4,079.7–21,833 total DALYs per year. In addition, GAP and biocontrol were both found to be effective strategies in the farm field. Meanwhile, the other three interventions had limited effectiveness in reducing total DALYs. In conclusion, this study could help farmers, processing plants, and government policy makers to alleviate aflatoxin contamination issues in the peanut production chain.
... Antara halangan terbesar kepada penguasaha makanan untuk melaksanakan GMP ialah melibatkan pengubahsuaian premis mereka, lebihlebih lagi yang melibatkan kos yang besar. Ketidaksesuaian premis yang asal menyebabkan sejumlah kos perlu dikeluarkan untuk pengubahsuaian atau penambahbaikan dan menjadi penghalang pelaksanaan GMP yang lebih baik dan berkesan (Fotopoulos et al. 2009;Gorayeb et al. 2009;Hielm et al. 2006;Mutlu et al. 2003;Taylor 2001). Berdasarkan keperluan GMP, premis makanan perlulah direkabentuk dan dibina supaya dapat mengawal risiko pencemaran. ...
Kajian ini dijalankan untuk mengenalpasti kefahaman pengusaha Perusahaan Kecil dan Sederhana (PKS) industri makanan terhadap keperluan premis yang memenuhi Amalan Pengilangan Baik (GMP) berdasarkan penafsiran terhadap Klausa 4.0 MS 1514: 2012 Rekabentuk dan Kemudahan-kemudahan. Kajian bertumpu di sekitar Lembah Klang, Malaysia. Komponen premis telah dibahagikan kepada 3 sub-elemen iaitu lokasi premis, premis dan kemudahan di dalam premis. Kajian yang dijalankan berbentuk soal selidik dan wawancara. Sejumlah 21 responden yang terlibat dalam soal selidik dan 5 responden yang terlibat untuk temubual. Keputusan menunjukkan bahawa keperluan Reka Bentuk dan Kemudahan adalah keperluan yang paling sukar untuk dipenuhi dengan diwakili 71% responden. Kos yang tinggi (67%) adalah faktor utama untuk keperluan GMP sukar dipatuhi. Faktor jurang penafsiran juga telah dibincangkan dalam kajian ini.
(This study was conducted to identify the understanding of food industry operators towards premises requirements on Good Manufacturing Practices (GMP) in accordance with interpretation of Clause 4.0 MS 1514: 2012 Design and Facilities. The focus area for this study was at small and medium enterprises (SMEs) in Klang Valley, Malaysia. The components of premise been divided into three sub 3 sub elements which are location of premise, premise and facilities in the premise. The study is based on survey questionnaire and interviews. A total of 21 respondents involved for survey questionnaire and 5 respondents involved for interviews. The results showed that needs of Design and Facilities is the most stringent requirement to comply with represent by 71% respondents. High cost (67%) is the main factor for the GMP requirements are difficult to be complied. The factors of the gaps’ interpretation also have been discussed in this study.)
... são fungos de grande importância durante o armazenamento dos alimentos. Quando esses fungos encontram adequadas condições de umidade e temperatura, pode ocorrer a contaminação dos alimentos por aflatoxinas, especialmente em sementes oleaginosas, como o amendoim e, em diversos tipos de cereais (GORAYEB et al., 2009). As aflatoxinas são um dos grupos de toxinas de maior importância ambiental e a forma B1 é a de maior potencial tóxico nesse grupo, com alta atividade hepatocarcinogênica e imunossupressiva (MAGNUSSEN, 2013). ...
Micotoxinas são contaminantes naturais, produzidos por fungos filamentosos e, podem ocorrer em altos níveis nos alimentos. Nos grãos de trigo, a presença de tricotecenos, um grupo de micotoxinas produzidas por Fusarium spp. e, aflatoxinas, produzidas por Aspergillus spp., representam um importante problema de saúde pública por serem tóxicas ao homem e
animais e muito estáveis aos processos no qual o trigo é submetido para obtenção de produtos industrializados. Uma forma de reduzir a contaminação dos alimentos por micotoxinas é através do uso do ozônio (O3) no processamento do alimento. Devido ao alto potencial oxidante do O3, esse pode degradar as moléculas das micotoxinas, tendo como consequência a
eliminação ou redução de seus efeitos tóxicos. Essa pesquisa teve como objetivos principais avaliar os efeitos de diferentes condições de ozonização na i) redução de micotoxinas (desoxinivalenol e aflatoxinas) em grãos de trigo; ii) redução nos níveis de fungos filamentosos; iii) influência nos parâmetros químicos, perfil de minerais e parâmetros
tecnológico dos grãos e da farinha obtida após o processamento e; iv) influência nas características sensoriais da farinha elaborada a partir dos grãos ozonizados. Em uma segunda etapa do projeto, um método para determinação de uma forma modificada do desoxinivalenol (DON), o desoxinivalenol-3-glicosídeo (D3G) foi otimizada e validada intralaboratorialmente, utilizando cromatografia líquida de alta eficiência com detector de arranjo de diodos (CLAE-DAD). Os resultados obtidos dos ensaios de ozonização demonstraram que o O3, nas condições experimentais utilizadas, reduziu a contagem de fungos totais em cerca 3,0 logs UFC/g de grãos e a contaminação por desoxinivalenol e aflatoxinas totais em até 64,3 % e 48,0 %, respectivamente. O processo de ozonização não influenciou de modo negativo a qualidade química, tecnológica e sensorial dos grãos de trigo, podendo ser utilizado como um excelente método para remediação da contaminação dos grãos
por fungos e micotoxinas. Resultados adequados também foram obtidos na validação do método de determinação de D3G por CLAE-DAD, demonstrando que o método é confiável para a determinação dessa forma mascarada do DON em grãos e trigo e, pode ser utilizado como um método alternativo a espectrometria de massas para tal análise.
... If adequate moisture and temperature conditions exist, Aspergillus spp. can produce mycotoxins, such as aflatoxin, especially in oilseeds and cereals (Gorayeb et al., 2009). Aflatoxins (AF) are one of the most important environmental toxins and the AFB 1 is the mycotoxin with the most toxicity in this group, with hepatocarcinogenic and immunosuppressive activities (Magnussen, 2013). ...
Food safety may be compromised by the presence of chemical contaminants, such as mycotoxins and pesticide residues. Mycotoxins are natural contaminants produced by certain species of filamentous fungi and can cause toxic effects on human health. Pesticide residues are any specified substance in food resulting from the use of a pesticide with toxicological significance. To protect consumers from these toxic substances, different food regulatory agencies have set maximum levels permitted in different raw materials and processed foods. However, recent research has demonstrated a high incidence of both mycotoxins and pesticide residues (not simultaneously) in foods marketed all around the world, sometimes with levels above the regulated limits. One way to reduce such contaminants is to use ozone (O 3) in food processing. Due to its high potential as an oxidant, O 3 or the radicals generated in the ozonation process react with mycotoxins and pesticide residues that lose their toxicity due to molecular degradation. In this review paper the recent research into using O 3 for gaseous ozonation and ozonized water to decontaminate food by eliminating and/or reducing mycotoxins and pesticide residues are discussed. Also the changes promoted in food quality attributes, the possible formation of degradation products of toxic relevance, as well as some perspectives for the future use of this technology in food processing are explored.
... Chemical control of AFs is expensive and not always efficient, but biological control reduces AF contamination before harvest by incorporating nontoxicogenic strains of the mold into the soil, where they compete with the toxicogenic strains for both infection sites and nutrients. These nontoxicogenic strains also protect the peanuts during storage [80]. ...
The peanut (Arachis hypogaea L.) is frequently contaminated with aflatoxins (AFs). Aflatoxins are toxic secondary metabolites – bifuran coumarins – produced by the fungi Aspergillus spp. AFs cause damage in animals and humans, including bleeding, vomiting, abortions, malformations, diarrhea and death. AFs can cause chronic liver damage and different cancers, immunosuppression, Reye’s syndrome, kwashiorkor and marasmus. For the present research, 58 samples of peanut were obtained: 48 were purchased from the three major markets of the 16 boroughs of Mexico City, and eight samples from Turkey and two from India were used for comparison. The extraction and quantification methods for AFs in peanut were validated. AFs from 25 g peanut samples were extracted with 100 mL of methanol/water (80:20 v/v) with one gram of salt. The roles of sample origin and types of AF were compared, and their significance was obtained through statistical analysis using the non-parametric Wilcoxon/Kruskal-Wallis tests. The limits of detection of AF (ng g-1) obtained from the calibration curves were AFB1 (0.1), AFB2 (0.01), AFG1 (0.01) and AFG2 (0.05). The results indicated that of the 58 samples, 80% were contaminated with AFB1, and all of them had total aflatoxins (AFt). The statistical analysis revealed a significant difference for AFB1, with the highest concentration of 44 μg kg-1 found in the Gustavo A. Madero Mexican borough. For AFB2, the highest concentration was 80 μg kg-1 from the Benito Juarez Mexican borough. Only traces of AFG1 were detected, with the highest of 0.64 μg kg-1 from the Tlahuac Mexican borough. Only traces of AFG2 were present. All samples had an average AFt of 8.53 μg kg-1.
... HACCP: Physical, chemical and biological risks which could affect the quality of food and could affect the safety of the food are controlled through an administrative system that is known as HACCP. Nowadays, from the first step of food receiving to the final step of product formation, HACCP is functional world-wide [8]. LITERATURE REVIEW: [9] discussed the successful application of quality management techniques and tools (QMT&T) by keeping in view a number of critical factors. ...
Total quality management (TQM) is a tool that helps the organizations to accelerate and compete in this global competitive environment by reducing costs and eliminating waste and delivering superior quality of product and services to their customer. This study aims to investigate that effective use of TQM tools and techniques at fried peanut processing plant that helps to increase performance. First of all precautionary risk assessment was done. After this assessment, the process steps that are most critical during the processing were identified. These recognized critical points of the process were then being executed in the Ishikawa diagrams. In this study, the main focused points were the identified critical control points of the process. Computation of risk assessment was done by calculating the risk priority number for each step. The steps that need more attention include raw material reception, segregated storage of red skin peanuts, oil quality check and frying, segregated storage of fried products, post allergen cleaning, and product final picking and inspection. And this is due to their high risk priority number. Corrective actions were taken for these steps and again risk priority number was calculated. Results of this study indicate that total quality management tools and techniques along with HACCP have a positive impact on smooth functioning of the system.
... HACCP has been widely used around the world to handle different types of products. In Bangladesh, HACCP plan was implemented for potato chips (Easdani & Bhuiyan 2013); In Brazil, HACCP was implemented for peanut processing (Castilho Gorayeb et al., 2009) ...
Jack Grealish is an aspiring entrepreneur. During his undergraduate in UCLA, he worked in his father's business, which focused on selling specialized foods. He became fascinated with the food industry and find out more what it entails. His investigation has unveiled the landscape of the food industry. Furthermore, he discovered that the hazard analysis and critical control points (HACCP) system implemented in the food industry was rather disjointed and could benefit from automation. He conducted a preliminary research about current HACCP development and determine to plunge ahead. Jack ponders about the possibility of integrating different pattern recognition methodologies in HACCP processes to improve the effectiveness of overall quality control at his company. Copyright © 2014, IGI Global. Copying or distributing in print or electronic forms without written permission of IGI Global is prohibited.
... There are other approaches to help ensure safety [8,82]. As stated by Bertolini et al., [83], Castilho-Gorayeb et al. [84], although HACCP is quite a structured program, it generally depends on some subjective analysis when determining the CCPs. Risk analysis becomes a powerful tool here since subjectiveness can be reduced since it deals with the probability of occurrence (risk) of a specific hazard. ...
Purpose of the review: This review focuses on the complex task of the final implementation of HACCP by fresh-cut processors. In the face of recent episodes involving safety of produce and fresh-cut products, HACCP has been highly demanded for this industry by regulators, politicians, consumers and the market. Findings: The incidence of illnesses caused by foodborne pathogens associated with produce and fresh-cut fruits and vegetables has increased. A great amount of research continues to be done on interventions and on a hurdle approach to prevent contamination by microbial and other hazards. In the literature the importance of the prerequisite programs: GAPs, GMPs and SSOPs, as part of any quality and safety integrated system wherein HACCP may be the last step, is continuously stressed. Limitations/implications: The adoption of integrated safety systems by the fresh-cut industry is very important. Apart from GMPs (mandatory), specific legislation and guidance for these products is necessary (microbiological criteria, guides for GAPs, SSOPs, HACCP). This may be a problem since the market exerts a lot of pressure on produce and fresh-cut processors, and the system may act functionally as a trade barrier for small and medium size businesses and for developing countries. Implementation of HACCP system should occur in later stages. Directions for future research: The dynamic of the fresh-cut market and the severe safety requirements imposed especially by consumers, will lead and it is already observed in recent literature, to reflections and analysis on food safety management systems and safety strategies using new approaches and philosophies.
... A large part of the peanut world production is used for human consumption, as a raw ingredient for processed foods, such as peanut butter and savory snacks, and produce oil and flour (Kaya et al., 2009;Nakai et al., 2008;Passone, Funes, Resnik, & Etcheverry, 2008). In Brazil, peanuts are commonly used to produce a variety of sweets and savory snacks (Gorayeb, Casciatori, Del Bianchi, & Thoméo, 2009). ...
The impact of two factors, genotype (G) and treatment (raw or roasted peanut) (T), on the chemical composition of peanuts was studied using a chemometric method and Tukey's test. The peanut genotypes evaluated were cultivar cavalo vermelho (CCV), cultivar cavalo rosa (CCR) and cultivar tatu (CTA), in both raw and roasted states. The total lipid contents in the CTA and CCR peanuts were 40 and 45%, respectively. These values did not vary significantly (P < 0.05) after roasting. CCV had the greatest total lipid content, but it decreased significantly after roasting (from 50% to 45%). The variation in the percentage of lipids in the CCV and CCR genotypes was not significant, in contrast to the CTA genotype. The fatty acid (FA) 18:1n−9 predominated in the CCR and CCV samples (50%), without any difference between their raw genotypes. The values for FA 18:1n−9 were lower in the CTA peanut (40%). The second most abundant FA was 18:2n−6 (CCV = 28%, CTA = 38% and CCR = 25%), followed by 16:0 (CCV and CCR = 16% and CTA = 11%). The other FAs found in the peanuts were 18:0, 20:0, 22:0, 24:0, 20:1n−9 and 18:3n−3. The contents of FAs 18:1n−9, 16:0, 20:0, and 20:1n−9 suffered significant reduction after roasting in all genotypes. ANOVA analysis of the influence of the main factors indicated that the contribution of the T variable for the majority of responses was low, being between 0.2 and 13%, except for FAs 16:0 and 18:3n−3 and for the saturated FA summations, which were 38, 60 and 22%, respectively. There was a significant contribution from the G factor for all responses, with values between 17 and 99%. The contribution of the interaction between the T and G factors was greater for the responses n6/n3 (56.6%) and for the FA 16:0 (23%). The other responses had values between 0.02 and 14%.
Jack Grealish is an aspiring entrepreneur. During his undergraduate in UCLA, he worked in his father’s business, which focused on selling specialized foods. He became fascinated with the food industry and find out more what it entails. His investigation has unveiled the landscape of the food industry. Furthermore, he discovered that the hazard analysis and critical control points (HACCP) system implemented in the food industry was rather disjointed and could benefit from automation. He conducted a preliminary research about current HACCP development and determine to plunge ahead. Jack ponders about the possibility of integrating different pattern recognition methodologies in HACCP processes to improve the effectiveness of overall quality control at his company.
Compliance to the premise requirements is one of certification criteria before Halal Certificates been issued and use of the Halal symbol on the products. Malaysian Standard MS 1514: 2012 Good Manufacturing Practice (GMP) For Food is important reference for the company to comply with premise requirements beside MS 1500 : 2009 Halal Food - Production, Preparation, Handling And Storage - General Guidelines (Second Revision). A study was conducted to harmonize the requirement of MS 1514:2009 and MS 1500:2009 for food premise design and facilities. The study is based on literature review. As conclusion, harmonizing between compliance to MS 1500 and MS 1514 on premises’ design and facilities requirements must be coordinated in order to avoid confusion among SMEs.
Hazard analysis and CCP determination are the backbones of HACCP development and implementation. The rest of HACCP principles depend on these two principles. A decision tree is used to assist in determining the CCP. There are two types of decision trees used in the HACCP system that is decision trees for raw material/packaging material and process step. Various methods of the decision tree used in HACCP systems not only have advantages, but it can also contribute to the confusion in its application by practitioners. Although the decision tree is just a tool to help determine the CCP, its use is a significant impact on the HACCP team, consultants and decision-making authority in determining the CCP and sensitive raw materials in a structured manner.
Biodegradability is defined as the capacity of to be broken down by the action of living things, such as bacteria and fungi being the main participants in the process of biodegradation in the natural world. The breakdown of materials provides them with precursors for cell components and energy for energy-requiring processes. Biodegradation is thus defined as catabolism. Some synthetic polymers, having chemical compositions resisting enzymatic attacks, can be microbially degraded with slower processes. Bioplastics is a term used for packaging materials derived from renewable resources and are considered safe to be used in food applications. In comparison to conventional plastics, the monomer composition of bio-based polymers can be differed by varying the producing strains, substrates and cosubstrates, and biopolymers such as polyhydroxyalkanoates (PHA), polylactic acid (PLA), polysaccahrides. PHAs are carbon-energy storage material accumulated intracellularly in a variety of microorganisms under controlled concentrations. Their biodegradability and possibility to be synthesised from renewable agricultural or even industrial wastes, make PHAs of considerable interest. Their main applications in food industry are serving as waterproof layer for the production of disposable food containers and utensils, cast films and cast sheets for thermoforming and utilisation as good odour and oxygen barriers.
The practical implementation of hazard analysis and critical control point (HACCP) and in particular the definition of the critical control points (CCPs) in the food industry is usually a complex structured task. This is particularly the case of small medium enterprise (SMEs), where quality/safety manager ability, knowledge of the production processes and “sensitiveness” is usually the discriminate for the proper identification and prioritization of risks. The same applies for the definition of causes which may lead to food safety hazards.This paper addresses the issues of how quality/safety managers can objectively and automatically implement the first and second principles of hazard analysis in the application of HACCP, which is the identification of risk priorities and of the related CCPs, by means of a structured, quantitative and qualitative methodology. The proposed methodology combines fault tree analysis (FTA) approach, for the analytical decomposition of the relevant steps in the manufacturing process of a food product, and fuzzy logic, for quantitative measures of occurrence likelihood.The practical implications of the methodology are finally tested through a real case application.
During the last three decades, Hazard Analysis Critical Control Point (HACCP) has been progressively introduced and applied for the benefit of the food industry. However, it should be recognised that HACCP systems have not been homogeneously implemented across all food industry sectors. Reasons for not implementing, maintaining and updating HACCP programmes cannot be explained purely in terms of unwillingness by manufacturers but rather by the presence of technical barriers that may impede the application of the system. Technical barriers represent all those practices, attitudes and perceptions that negatively affect the understanding of the HACCP concept and hence the proper and effective implementation and maintenance of the HACCP principles. This paper describes the potential barriers that may impede the correct use of HACCP before it has been implemented, during the process of implementation and after it has been implemented. Until barriers impeding HACCP have been resolved, HACCP systems will not be implemented throughout the whole food chain and it will not be able to reach its full potential as prerequisite for the international trade of foodstuffs.
Moulds and associated mycotoxins are important factors adversely affecting foods produced using contaminated plant products or animal products derived from animals fed on contaminated feeds. Mycotoxins are toxic to humans and animals, which explains the major concern of food and feed industries in preventing them from entering the food chain. Prevention is essential since there are few ways to completely overcome problems once mycotoxins are present. Toxin-producing moulds may invade plant material in the field before harvest, during post-harvest handling and storage and during processing into food and feed products. Thus, toxigenic fungi have been roughly classified into two groups (i) field fungi; (ii) storage fungi. The Fusarium genus, e.g. F. verticillioides (formerly F. moniliforme), F. roseus, F. tricinctum and F. nivale, are ubiquitous soil organisms, which may infect cereals directly in the field thereby, increasing fumonisins, trichothecene, and zearalenone levels (depending on the species) during growth, ripening of grain and at harvesting. Fusarium sp. can have deleterious effect on plants and decrease plant productivity. Many species can infect heads of wheat and other small grain cereals in fields causing head scab or blight (FHB). Ear rot also can be caused by Fusarium sp. growing on maize. Furthermore, fungi can grow on the non-grain part of plants producing large amounts of mycelium towards the stem where it colonizes the vascular bundles, which inhibits the transfer of nutrients in the upper part of the plant. On the contrary, Fusarium sp. does not significantly contribute to the storage fungi or to the fungal contaminants found only on damaged grains. Due to the multiple possible origins of fungal infection, any prevention strategy for fungal and mycotoxin contamination must be carried out at an integrative level all along the food production chain. Three steps of intervention have been identified. The first step in prevention should occur before Abbreviations: FHB, Fusarium head blight; HSCAS, hydrated sodium calcium aluminosilicates; QTLs, quantitative trait loci * Tel.: +33 4 73 62 40 54; fax: +33 4 73 62 46 59.
The effects of the gas barrier characteristics of three films (ASI, ASII and ASIII) and storage temperature on the growth of, and aflatoxin production by, Aspergillus flavus in peanuts packaged in air and under a modified gas atmosphere of CO2:N2 (65:35) were investigated. Mold growth was barely visible in air packaged peanuts using high-medium barrier films (ASI and ASII) and stored at 20°C with more extensive growth occurring in air packaged peanuts stored at 25 and 30°C. Extensive mycelial growth and sporulation occurred in all air packaged peanuts in a low barrier film (ASIII), especially at 30°C. Gas packaging inhibited mold growth in peanuts packaged in a high gas barrier film at 20°C. However, mold growth occurred in gas packaged peanuts packaged in film ASII at higher storage temperatures while extensive mycelial growth was observed in all peanuts packaged in film ASIII irrespective of storage temperature. Levels of aflatoxin greater than the regulatory limit of 20 ng/g were detected in all air packaged peanuts with the highest level of aflatoxin (∼76 ng/g) being detected in peanuts packaged in a high gas barrier film ASI. Aflatoxin production was inhibited in gas packaged peanuts using a high barrier film. However, higher levels of aflatoxin were detected in all gas packaged peanuts in medium-low gas barrier films (ASII and ASIII), particularly at higher storage temperatures. This study has shown that MAP using a CO2:N2 (65:35) gas mixture was effective in controlling aflatoxin production by A. flavus in peanuts to levels less than the regulatory limit of 20 ng/g. However, the antimycotic effect of low O2-high CO2 atmospheres is dependent on the gas barrier characteristics of the packaging films, especially at higher storage temperatures.
Because of its inability to detect hazards that occur a low incidence, the quality control system was supplanted by the HACCP system to provide assurance of food safety. The global use and success of the HACCP system in the food processing industry created false expectations that it could be used successfully in all steps of the food supply chain, from Farm to Table. However, the lack of definitive critical control points that could eliminate or control identified hazards prevents the effective use of HACCP in all steps of the supply chain. Food safety measures can be used at each step in the supply chain, but most of these measures will be prerequisite programs rather that critical control points from a HACCP system. To better focus on the application of effective food safety control measures, we must communicate in terms of “Farm to Table Food Safety”, rather than “Farm to Table HACCP”.
An experiment was conducted to study the effects of liming and drying method on Ca nutrition, fungus infection and aflatoxin production potential on peanut (Arachis hypogea) grains. Peanut cv. Botutatu was grown in the absence or presence of liming to raise the base saturation of the soil from 20 to 56%. Calcium contents of the soil were increased from 5.5 to 14.6 mmol(c)kg−1 and pH from 4.2 to 4.9. After harvest, plants and pods were dried in (1) shade, (2) field down to 100 g water kg−1, (3) field down to 250 g water kg−1 and transferred to a forced-air oven at 30°C, (4) field down to 360 g water kg−1 and transferred to a forced-air oven at 30°C. Calcium contents were analyzed in the grains, pericarps and seed coats. The incidence of Aspergillus spp., Penicillium spp., Rhizopus spp. and potential aflatoxin production in vitro were evaluated, as well as the seed coat thickness. The seed coat was thicker when peanut was grown in the presence of lime, leading to a decrease in seed infection by Aspergillus spp. and Penicillium spp. When plants were dried in shade, the growth of aflatoxinogenic fungi was independent of liming. However, in plants dried in the field or field + oven, the development of these fungi was decreased and even suppressed when the Ca content of the seed coat was increased from 2.2 to 5.5 g kg−1.
The combined effects of water activity (aw), storage temperature, headspace oxygen and carbon dioxide concentrations on the growth of, and aflatoxin production by Aspergillus flavus on sterile peanuts were examined using a process optimization technique termed response surface methodology (RSM). Regression analysis of the data indicated that aw, storage temperature and initial headspace oxygen concentration were all significant factors (P < 0.001) affecting the growth of, and aflatoxin production by A. flavus. Extensive growth and aflatoxin production occurred during the first week of storage in most treatment combinations. Maximum growth occurred in peanuts with an aw of 0.97, a storage temperature of 25 degrees C and headspace oxygen of 10% (balance 60:40 carbon dioxide:nitrogen), after 21 days of storage while maximum aflatoxin production occurred at a lower aw of 0.94, after 21 days under similar storage/gaseous conditions. In several treatment combinations, where high levels of aflatoxin (> 20 ng/g) were initially detected, aflatoxin concentration decreased during storage to levels less than the current regulatory limit of 20 ng/g. This study has shown that A. flavus can grow and produce aflatoxin in carbon dioxide enriched atmospheres in the presence of oxygen. It also emphasizes the combined effect of several 'barriers' to inhibit and reduce aflatoxin in MAP products containing various levels of residual oxygen.
The development and use of a simple tool for food safety risk assessment is described. The tool is in spreadsheet software format and embodies established principles of food safety risk assessment, i.e., the combination of probability of exposure to a food-borne hazard, the magnitude of hazard in a food when present, and the probability and severity of outcomes that might arise from that level and frequency of exposure. The tool requires the user to select from qualitative statements and/or to provide quantitative data concerning factors that that will affect the food safety risk to a specific population, arising from a specific food product and specific hazard, during the steps from harvest to consumption. The spreadsheet converts the qualitative inputs into numerical values and combines them with the quantitative inputs in a series of mathematical and logical steps using standard spreadsheet functions. Those calculations are used to generate indices of the public health risk. Shortcomings of the approach are discussed, including the simplifications and assumptions inherent in the mathematical model, the inadequacy of data currently available, and the lack of consideration of variability and uncertainty in the inputs and outputs of the model. Possible improvements are suggested. The model underpinning the tool is a simplification of the harvest to consumption pathway, but the tool offers a quick and simple means of comparing food-borne risks from diverse products, and has utility for ranking and prioritising risks from diverse sources. It can be used to screen food-borne risks and identify those requiring more rigorous assessment. It also serves as an aid to structured problem solving and can help to focus attention on those factors in food production, processing, distribution and meal preparation that most affect food safety risk, and that may be the most appropriate targets for risk management strategies.
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