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A.P.Gandhi
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Project No: 583
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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),
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soy nuts and
Gandhi
soy sprouts.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,
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preparing the decision tree,
establishing the critical
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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.
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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 .
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Date of Start: April 2007
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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
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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
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in the chain .
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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.
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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.
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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
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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.
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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.
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Areas subject to flooding unless
sufficient safe guards are provided.
Areas prone to infestation of pests.
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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.
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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.
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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.
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Floors should be constructed to
allow adequate drainage and
cleaning.
Ceilings and overhead fixtures
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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
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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.
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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.
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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.
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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.
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Potable water should be as
specified in WHO Guidelines.
Non potable water shall have a
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Drainage and waste disposal:
Adequate drainage and waste
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Cleaning:
Adequate facilities, suitably
humidity controls.
Food grade packaging.
Maintenance of equipment.
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Maintenance and Sanitation
Adequate level of maintenance of
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Personal Hygiene
Health Status:
People known or suspected to be
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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
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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.
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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
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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.
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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).
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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.
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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.
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APP LI CA TI ON
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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.
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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.
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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.
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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.
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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.
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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.
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7. Determine Critical Control Points
There may be more than one CCP at
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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.
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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
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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
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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.
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TRA INI NG
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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
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It was stored in airtight containers
till further use.
Different soy based foods were
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FAO/WHO (2006) guidelines were used
for the preparation of HACCP plans.
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Full Fat S oy flo ur
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Table1.Product description
1. Product name Full Fat Soy flour
2. Important product Aw < 0.5;FFA < 1%; Total
characteristics of end product microbial counts < 50000/g
3. How the product is to be Normally fortified with other
used cereals/millets/pulses at 10-
15% level in the preparation of
traditional recipes.
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Table 2.P roduct ingr edi ents and incoming
mater ial
Soybeans Packaging Dry ingredients Water
material
2.Receiving P 3. Receiving P
1. Receiving P 7. Storing B C P
4. In taking
6.Storing B C P
5.Storing B P 10. Dumping
9.Inspecting B P
8. Cleaning P
20.Inspecting B P
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22. Storing B
Table 3.Un add resse d Haz ards:
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Process Hazard Critical Monitoring Deviation HACCP
step description limits procedure procedures records
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should be removed.
They should be graded.
the GMPs.
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Storage of full fat flour (CCP-12):
Both the temperature and relative
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)
Microbiology:
Total plate count: 10,000/g
20,000/g max 50,000/g
Total coli forms: Nil
100/10g max 120/10g
Salmonella:
Negative/100g Nil
10/100g
E.coli
Negative/100g Nil
15/100g
Staphylococcus:
100/10g max Nil
Yeast: 100/10g max 135/10g Nil
Mold: 100/10g max. 123/10g Nil
110/10g
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Quality standard With out HACCP With HACCP
expected
Protein solubility:
PDI 20-80% 25% 75%
TI: less than 75% of
original. 50% 80%
Urease activity: Nil
Nil Nil
Available lysine: Min
5.5g/6g N
4.2g/6gN 6.2g/6gN
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 10-
14,2008.
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.