How To Make High Energy Biscuits

Transcription

1 Technical Specifications of: High Energy Biscuits -HEB Specification reference: HEB Version: 13.0 Date of issue: 25 February 2013 Developed: Van Hoan NGUYEN, OSPFQ-WFP Reviewed: Shane PRIGGE, OSPFQ-WFP; Approved: Shane PRIGGE, OSPFQ-WFP 1. INTRODUCTION 1.1 Product purpose WFP High Energy Biscuits (HEB) are biscuits (small baked bread or cakes) that are supplemented with a premix of vitamins and minerals. This ready to eat food participates to the covering of urgent needs in the acute phase of an emergency situation during which population is not able to cook due to a lack of access to basic facilities (clean water, cooking equipment ). Their use is also extended to a complement food ration (use as snacks) to provide vitamins and minerals in regions/population where diet is subjected to nutritional deficiencies. HEB can be used also to prevent micronutrients deficiency of young children and school age children. 1.2 International Standards WFP High Energy Biscuits shall comply, except when specified otherwise in this contract, with the following guidelines or standards of Codex Alimentarius: Guidelines on Formulated Supplementary Foods for Older Infants and Young Children, CAC/GL of the Codex Alimentarius. Code of Hygienic Practice for Foods for Infants and Children CAC/RCP of the Codex Alimentarius; Recommended International Code of Practice: General Principles of Food Hygiene CAC/RCP Rev including Annex Hazard Analysis and Critical Control Point (HACCP) System and Guidelines for its application. General principles for addition of essential nutrients to foods: CAC/GL (amended 1989, 1991), of the Codex Alimentarius. 1 / 7

2 2. RAW MATERIALS 2.1 Main ingredients HEB shall be manufactured from fresh and good quality, free from foreign materials, substances hazardous to health, excessive moisture, insect damage and fungal contamination and shall comply with all relevant national food laws and standards. Requirements for the raw materials are: Wheat flour should conform to Codex STAN Soy flour/soy protein should conform to Codex STAN (for soy) or Codex STAN (for soy protein). Sugar should conform to Codex STAN Skimmed milk powder should conform to Codex STAN It shall be accompanied by a melamine-free certificate. - Maximum level aflatoxin M1: < 0.5 mcg/kg milk (recommended methods ISO 14501/IDF 171: or ISO 14674/IDF 190: ). Additives - Lecithin shall be in proportion as specified in the Codex STAN Raising (SODA) agent as specified in the Codex STAN , the maximal value is determined by the GMP principles. - Shortening: the only shortening agent allowed is palm oil as per Codex STAN Artificial flavoring agents are not allowed except ethyl vanillin and vanillin: 7mg/100g - Other additives must comply with Codex STAN and Codex STAN Other raw materials need to comply with Codex or relevant regulations. Raw materials must be stored under dry, ventilated and hygienic conditions. Only safe insecticides (i.e. phosphine) may be used for fumigation control. Where needed, fumigation must be performed by certified operators. 2.2 Vitamins and minerals Complete micronutrient premixes must be purchased from a WFP approved supplier: BASF (Stern Vitamin), DSM, Fortitech, Nicholas Piramal, Hexagon Nutrition or their authorized dealers and GAIN premix facility. Addresses of premix suppliers are on Micronutrient premixes must be delivered to the processor of HEB with a complete Certificate of Analysis as well as with a Proof of purchase of premixes. The two documents must be presented with other documents for payment. Micronutrient premixes must be stored in a dry, cool and clean place. 1 Milk and milk powder: determination of aflatoxin M1 content, clean up by immunoaffinity chromatography and determination by HPLC. 2 Milk and milk powder: determination of aflatoxin M1 content, clean up by immunoaffinity chromatography and determination by Thin Layer Chromatography. 2 / 7

3 3. PROCESSING 3.1 Formula HEB is manufactured according to the formula that supplier usually used for the production of their normal biscuit. 3.2 Food safety and risk assessment at manufacturing premises For compliance with Codex standards the processor must be able to demonstrate by principle and practice the adoption, implementation and recording of: Good Manufacturing Practice Hazard Analysis Critical Control Point program In this context an appointed WFP Inspector / Quality Surveyor is entitled to visit the factory without prior notice during any period when WFP product is being manufactured to check that the GMP and HACCP systems are in place. The Inspector / Quality Surveyor may request to see: Records (i.e. names of people in charge of the process and quality control, temperatures of the process, mixing times / quantity, cleaning schedules, etc). Procedures (e.g. cleaning, personnel hygiene, HACCP, sampling and analysis). Instructions (e.g. process instructions, cleaning instructions). The quality manual for the process or factory. The manufacturer must be registered under national food law as a processor of foods for human consumption. 4. PRODUCT SPECIFICATIONS 4.1 Moisture content 4.5% maximum 4.2 Nutritional value: it shall contain the following nutritional value per 100 g dry matter: Energy 450 kcal minimum Protein g (N x 6.25) Fat 15.0 g minimum Sugar (total) g Fiber (crude) 2.3 g maximum Ash (total) 3.5 g maximum 4.3 Micronutrient supplement HEB must be fortified to provide the following net micro nutrient supplement per 100g of finished product: 3 / 7

4 Table 1: Micronutrient rate and chemical form Target Chemical form Vitamin A-Retinol 250 µg Palmitate 250 CWS Vitamin B1 0.5 mg Thiamine mononitrate Vitamin B2 0.7 mg Riboflavin Niacin 6 mg Nicotinamide Pantothenic acid 3 mg Calcium d-pantothenate Vitamin B6 1. mg Pyridoxin hydrochloride Folic acid 80 µg Folic acid Vitamin B12 2 µg Vitamin B12 1% in manitol Vitamin C 20 mg Ascorbic acid coated Vitamin D 1.9 µg Vit D3 100 CWS Vitamin E 5 mg Vit E 50 CWS Calcium 250 mg Calcium carbonate Magnesium 150 mg As magnesium oxide Iron 11 mg Ferrous fumarate Iodine 75 µg Potassium iodate Note: Variable levels of micronutrients (i.e iron, zinc, calcium etc.) naturally present in raw materials may lead variable of micronutrients in finished product. 4.4 Microbiology The following levels of microbiological contamination in the finished product shall not be exceeded: Table 2: Limit of microorganisms in HEB Microorganisms Mesophyllic aerobic bacteria Coliforms Escherichia coli Salmonella Staphylococcus aureus Bacillus cereus Enterobacter sakazakii Yeasts and moulds Limits Max 10,000 cfu per g Max 10 cfu per g Absent in 10 g Absent in 25g <10 cfu per g Max 10 cfu per g Absent in 10 g Max 100 cfu per g 4.5 Additional Requirements Organoleptic: it shall have a pleasant smell and palatable taste. Broken: percentage of broken biscuit shall not be more than 5.0% (by weight). Weight: one biscuits should weigh between 5 g and 10g. Peroxide value: shall not be above 10 meq/kg fat. Shelf life: it shall retain above qualities for 24 months from date of manufacture when stored dry at ambient temperatures prevalent in the country of destination. 4 / 7

5 Safety HEB shall be free from objectionable matter; not contain any substances originating from micro-organisms or any other poisonous or deleterious substances, heavy metals or pesticide residues, in amounts which may represent a hazard to health. - Toxins permitted level of aflatoxin M1: < 0.5 ppb - Heavy Metals Arsenic (As) < 0.10 ppm Cadmium (Cd) < 0.10 ppm Lead (Pb) < 0.02 ppm Mercury (Hg) < 0.20 ppm - Pesticide residues Carbamate Organochlorine Organophosphorus Pyrethroid - Melamine max 2.5 mg/kg Other requirements o Free from radioactivity o Free from Genetically Modified Organisms (GMO) (if required by the contract) o Suppliers shall have to check the quality of their product and guarantee that HEB is fit for human consumption 5. PACKAGING Package Biscuits shall be packed in metalized laminate OPP 20micron/PR 3C/DRY/VMCPP 25micron packages. Each package shall contain 50 grams, 75 grams, 100 grams or 250 grams biscuits (to be specified in the contract). Carton Individual packages shall be stuffed in strong cardboard cartons suitable for multiple handling. 100 of these or 40 of these respectively to be stuffed in one carton box of 10kg net with necessary marking. N.B. About bags of silica gel of at least 1 Kg each should be placed in each container in order to absorb moisture. In addition craft paper should be laid to all sides of the container. Biscuit packaging should include the following information: production date (month/year) best before date (month/year) nutritional information per 100 g this product contains no lard not for individual sale "World Food Programme + WFP logo " Additional marking as per contractual agreement. 5 / 7

6 6. MARKING Cartons shall be marked at seller s expense with the following information: In letters measuring 1.0 to 1.5 cm on the cartons: net weight month and year of production full name or code of the production enterprise ingredients, nutritional information WFP logo (in letters of 5 cm) Additional marking as per contractual agreement. 50 grams, 75 grams, 100 grams or 250 grams biscuits (to be specified in the contract) individual packages to be marked with the following information: World Food Programme + WFP logo + donor (to be advised later) Nutrition information: Calories, minerals, vitamins per 100g of product. This product contains no lard Not for individual sale Month and year of production and best before date. Additional marking as per contractual agreement. 7. STORING HEB must be stored under dry, ventilated and hygienic conditions. 6 / 7

7 8. ANALYTICAL REQUIREMENTS The principal tests in table 3 must be performed in order to check if the quality of HEB meets above requirements. Additional analyses shall be defined in case of further quality assessment. Table 3: List of compulsory tests and reference methods No Tests Limit Reference method (or equivalent) 1 Moisture content Max 4.5 % AOAC , Energy (by calculation) Min 450 kcal/100g 3 Protein g/100g AOAC Fat Min 15.0 g/100g AOAC , Sugar (total) g/100g IFFJP method 14, Crude fiber Max 2.3g/100g AOAC Ash (total) Max 3.5 g/100g ISO Vitamin A- Retinol 250 mcg/100g AOAC Iron 11 mg/100g AOAC Mesophyllic Max 10,000 cfu per g ICC No aerobic bacteria AACC Coliforms Max 10 cfu per g AOAC Escherichia coli Absent in 10 g AOAC Salmonella Absent in 25g AACC 42-25B Staphylococcus <10 cfu per g 14 aureus AACC 42-30B 15 Bacillus cereus Max 10 cfu per g AOAC Yeasts and 16 moulds Max 100 cfu per g ICC No Melamine Max 2.5mg/kg fs_management/melamine_methods.pdf 18 Aflatoxin M1 < 0.5 ppb AACC Peroxide value Max 10 meq/kg fat AOAC Organoleptic (smell, taste, color) and broken GMO (only if required) Pleasant smell and palatable taste, typical color, Max 5.0 % broken (by weight) Negative (< 0.9% of GMO material) Sensory, Weighing 7 / 7