How To Ensure Food Safety

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1 HAC Systems in Brazilian Macadamia Processing Pedro Luis Blasi de Toledo Piza 1 & Isabela Miranda de Toledo Piza 2 1 UNESP, Universidade Estadual Paulista, School of Agronomical Science, Department of Agriculture Energy, Brazil, pedropiza@terra.com.br 2 UNESP, Universidade Estadual Paulista, Institute of Bioscience, Department of Chemistry and Biochemistry, Brazil, isabelapiza@terra.com.br Abstract In 2002, Brazil produced 560 tons of macadamia kernels (2,600 tons in shell), ranking as the 7 th world macadamia nut producer. Around 90% of the Brazilian production was exported mainly to the United States and also to Europe and Japan. The customer countries quality requirements, the high competition and the increasing world concern about suitability and food safety, stimulated the development of the Hazard Analysis and Critical Control Point (HAC) for macadamia plant processing. The HAC system has been indicated as the most efficient method to guarantee suitability and food safety. Therefore, this study aimed at the application of this system in the processing of macadamia industry. The receiving, drying, manual selection and packing steps were considered critical control points due to the possibility of contamination by biological, chemical and agents. Control measures and critical limits were indicated, monitoring procedures and corrective actions were adopted with verification mechanisms and registers. Procedure manuals were developed to stimulate the consultation and to be easily understood by the user. The observed results reported an effective hazard control that threatened suitability and food safety. Key words: macadamia, HAC, food safety 1 - Introduction The Hazard Analysis and Critical Control Point system (HAC) began along with the rth American space program 35 years ago. Since 1971, when the three HAC principles were presented at the US Conference on Food Protection, the interest on this subject was increased by a food safety warrant system (Gelli, 2001). In Brazil the program established since vember 26 th, 1993, when the Health Governmental Office provided a directive number 1428 with the guidelines to apply Good Manufacturing Practices (GMP), Services Delivery and HAC system on food area (Brazil, 1993). Due to a natural demanding for quality increase on processed food production, Agriculture and Supply Department published a directive n 46 in February 10 th, 1998, which meets postulated national commitments encompassed by the World Commerce Organization and the Codex Alimentarius requirements. This directive standardizes the guidelines for the provision of a General Proceeding Manual to elaborate a HAC plan (Brazil, 1998). HAC is based on a systematic investigation to identify, evaluate and control food-processing hazards on production, distribution and consume steps. HAC basic concept is prevention rather than inspection of the final product. The aim, besides preparing food in a safety way, is to guarantee its suitability. This system has been adopted worldwide, not only to ensure safety, but also to reduce expenses and increase profits, once it minimizes losses and rework, making a great part of laboratory analysis useless on the traditional control system, besides making control process transparent and liable. Hazards, which affect food safety, may be defined as an unacceptable presence of biological, chemical and contaminators on raw material, products under fabrication and final product (Profiqua, 1995) The primary condition for HAC implantation plan is to verify if Good Manufacturing Practices are being respected. GMP (Good Manufacturing Practices) are considered pre requisites and hygienic procedures, education and personnel training must be implanted previously. When Good Practices are not respected, there is no reason for implementing HAC system (Gelli, 2001). Thus, the aim of this work was to suggest a HAC (Hazard Analysis and Critical Control Point) for a macadamia nut industry validating all production steps from nut in shell to shipment. 2 - Material and Methods In macadamia nut, biological hazards are represented by microorganisms, pathogenic and its toxins, virus, parasites and protozoa; the hazards are macadamia shell, sticks, stones and metals. Chemical hazards are disinfectant

2 , heavy metals, pesticides and fertilizers. Different kinds of hazards may raise variable severe consequences for human beings, depending on pathologies severity (Sebrae, 2000). Yeast and mold analysis, Coliforms, E. coli and Salmonella in macadamia nuts are used as suitability control. The presence of this microorganisms in higher than permitted levels after processing, corroborates field contamination and consequently a deficient sanitary condition or that contamination occurred after this operation, a clear indication that hygienic procedures or Good Manufacturing Practices are below indicated standards (Santos et al, 2000). As a support element for HAC implantation guides and tables developed by Senai - National Department (2000) were used, which relates hazards and its characteristics, as well as preventive measures, which may be adopted to control them. 3 - Results and Discussion Description of the product Name of the product: macadamia in natura Important characteristics of the final product: Moisture content, Peroxide value, Free Fatty Acids, Coliforms, E. coli, Salmonella, Yeast and Mold, Aflatoxin Product used by the consumer: Consumed directly in ice creams, sweets or toasted and salted in several dishes. Container characteristics : Vacuum packed in 25 lb aluminum bags (11.34 kg) Validity: 1 year Sale Outlet of the product: The product is exported to the USA and is sold in supermarkets, stores, etc. Label instructions: Keep in a fresh and dry place. After opening it, consume in 5 days. Special controls during distribution and housing: Avoid exposition to high temperatures 2

3 3.2 - Flow Diagram NUT IN SHELL PACKAGE C 1 INCOMING - STORAGE C 2 Water + Chlorine DISINFECTION - DRYING Hot water - NUT IN SHELL SORTING Deteriorated FURNACE WEIGHING Good C 3 CRACKING BOILER Shell ELECTRONIC COLOR SORTER FURNACE C 4 Kernel MANUAL SELECTION RESIDUE STYLE SIZING C 5 INSPECTION AND QUALITY CONTROL METAL DETECTOR - VACUUM PACKAGE STORAGE SHIPMENT 3

4 3.3 Process Description Macadamia nuts are manually collected from the ground when they naturally fall ripped from the trees remaining subjected to insects, in contact with decomposed organic matter and to the presence of rodents. If, for instance, the fruit remains on the ground for a long period, especially under wet conditions, the nuts will become molded, discolored and the percentage of germinated ones will increase (TOLEDO PIZA, 2000). Thus, Good Management Practices on the field should be adopted to decrease potential hazards like and parasites, which can reach the product from soil, fertilizers, water irrigation, dust and food s. Besides that, pesticides used may also be a hazard to consumers representing a chemical contamination. The nut in shell is received and goes through a raw material receiving condition analysis; it is inspected to evaluate its general conservation condition. Incoming step is considered a C (Critical Control Point) due to the possibility of receiving contaminated product by microorganisms, pesticides and pieces of sticks, stones, several debris, from the orchard. After incoming, the nuts are stored in aired silos, and then disinfected with water and chlorine solution, 50 ppm free chlorine, aiming at strongly reduce the amount. This step is considered a C due to the possibility of chemical contamination because of the use of super-chlorinated water, or survival of soil microorganisms. The following step, nut drying, takes place inside drying silos with automatic controlled temperature by sensors until 1.5% kernel moisture content. After drying nut in shell is selected, in which, deteriorated, bored, chinked and smaller than 17 mm nuts are manually disposed of. These steps were considered Control Points () once they can endanger the product safety, but they are mainly controlled by Good Manufacturing Practices. The cracking was considered a C where there is a nut contamination hazard by microorganisms surviving in the shell, and also a contamination hazard by shell which may imbed the nut. Following production steps there is an electronic color sorting, manual selection and style sizing, which are also procedures controlled by Good Manufacturing Practices, they are prerequisites for HAC program efficiency. In these steps, manual selection was considered C due to the contamination hazard because of shell. After the style sizing, there is an inspection and quality control, which was also considered C due to the possibility of product recontamination Analytical and Control Tables A) Biological Hazard Analysis Ingredients/Steps Biological of the process Hazards Macadamia Yeast, mold, Rationale Severity Risk Preventive Measures Present in the soil High High Field GMP Qualified suppliers Incoming Yeast, mold, Soil, manipulator, transport High High Training Material disposal Storage Yeast, mold, Present in shell High Medium GMP, training Disinfection Bacteria Present in the water High Low GMP, potable water control Manual Selection Yeast, mold, High Low GMP, training Quality Inspection and Control Yeast, mold, High Low GMP, training Vacuum Package Yeast, mold, Practice failure High Low Training, preventive equipment maintenance 4

5 B) Chemical Hazard Analysis Ingredients/Steps Chemical Hazards Rationale Severity Risk Preventive Measures of the process Macadamia Chemical Residues Used in orchard High Medium Field GMP Qualified suppliers Incoming Chemical Residues Used in orchard High Medium Field GMP Qualified suppliers Disinfection Chlorine Residue Over Chlorinated water High Low GMP, potable water control and chlorine residual level Manual Selection Cleaning and disinfectation chemical products High Low GMP, training Quality Inspection and Control Cleaning and disinfectation chemical products High Low GMP, training C) Physical Hazard Analysis Ingredients/Steps Physical Hazards Rationale Severity Risk Preventive Measures of the process Macadamia Sticks, stones, Present in orchard High Low Field GMP several debris Incoming Sticks, stones, Present in orchard High Low Selection and disposal several debris Manual Selection Shells, metal debris Equipment, selection failure High Low GMP, training, metal detector Quality Inspection and Control Shells Handler failure High Low GMP, training D) Table of Hazards which are not controlled in the Establishment (Final Product) Name of the Product: Macadamia in natura Identified Hazards related to sources outside the Preventive Measures (cooking instructions, consumer establishment and others) Recontamination by deteriorated microorganisms after the Orientation related to how to use and preserve the product on package opening by the consumer fostering pathogens package label. growing conditions. Recontamination by deteriorated microorganisms on commercialization, distribution, fostering pathogen development conditions. Good Storage Practices, package adequate piling, adequate handling and transportation. E) Raw Material Identification/ Critical Ingredient Name of the Product: Macadamia in natura Raw Material Identified Hazards and category (biological, chemical and/or ) Question 1: May the hazard occur in unacceptable levels? Macadamia Biological: Yeast and mold, Salmonella sp, Aflatoxin, E. coli, Coliforms. Question 2: Will the process eliminate or reduce hazard to acceptable levels? Critical Chemical: Chemical Physical: Sticks, stones, ground, orchard debris 5

6 F) C Determination Process Step Macadamia Incoming Storage Significant hazards (biological, chemical and ) Chemical: chemical Physical: sticks, stones. Chemical: chemical Physical: sticks, stones. Disinfection Biological: Chemical: chlorine Drying Biological: molds Nut in shell selection Cracking Chemical: cleaning product Physical; shells, Manual selection Inspection and quality control Vacuum package metals debris Chemical: cleaning product Physical; shells, metals debris Physical: shells, metal debris Does the pre requisite program control the hazard? Are there hazard preventive measures? Does this step eliminate or reduce hazard to acceptable levels? May the hazard increase to unacceptable levels? Will a subsequent step eliminate or reduce hazard to acceptable levels? C C 1 Biological chemical C 2 Biological chemical C 3 biological C 4 C Conclusion Besides being a law-regulated process of Brazilian food industries, HAC is still very little used. In the case of Macadamia, which 90% of the production is exported, the possibility of tariff free impediments in consumer countries 6

7 obliges the establishments to follow international safety and suitability standards, this fact may be faced by the Brazilian industries as a sole opportunity for qualitative betterment and social responsibility demonstration. Considered as the best flavored nut in the world, Macadamia reaches the highest market prices and attracts demanding consumers. Addressing as an initial study, one concluded that HAC system is an excellent management tools, allowing a practical and effective way to control hazards in a macadamia nut establishment. Plan implantation, following the suggested steps, will provide the production of a safety macadamia with a higher quality than the ones found in the market. 5 - Bibliography BRASIL. M.A.A. Diário Oficial da União. Seção 1, nº24-28, 16 de março Portaria nº46 Manual Genérico de Procedimento para APPCC em indústrias de produtos de origem animal, 10 de fevereiro GELLI, D.S. Manual de Controle Higiênico-Sanitário em Alimentos / Eneo Alves da Silva Jr. São Paulo: Livraria Varela, Capítulo, 19. 4º edição. PROFIQUA. Manual de Análises de Perigos e Pontos Críticos de Controle APPCC. Campinas, SBCTA, p. SANTOS, D.M.S., BERCHIERI JR., A., FERNANDES, S.A. TAVECHIO, A.T. & AMARAL, L.A. Salmonella em carcaças de frango congeladas. Pesquisa Veterinária Brasileira 20(1):39-42, SEBRAE/CNI/SENAI. Guia para elaboração do plano APPCC geral. Rio de Janeiro, Cetec, 60p., TOLEDO PIZA, P.L.B. Secagem e Escoamento da z Macadâmia (M. integrifolia) em silo Secador de Fundo Cônico. Dissertação/Mestrado. FCA/UNESP. Botucatu