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Content - Content - Datasheet - Flow charts - Risk assessment Datasheet code Product Definition 2.012 bean expeller By-product of the recovery of oil / butter through pressing out of cocoa beans, Theobroma cacao L. 2.013 bean, extracted By-product of the recovery of cocoa butter through extraction from cocoa bean expeller. 2.010 butter acid oils from chemical refining 2.014 butter fatty acids distillates from physical refining 2.015 deodistillates (treated) Product obtained during the deacidification of cocoa butter by means of alkali, followed by an acidulation which subsequent separation of the aqueous phase, containing free fatty acids, oil and natural components of the cocoa beans such as mono- and diglycerides, lecithin and fibres. Product obtained during the deacidification of cocoa butter by means of distillation containing free fatty acids, oil and natural components of the cocoa beans such as mono- and diglycerides, sterols and tocopherols. By-product of the chemical refining of cocoa butter, which is subsequently treated to reduce dioxin and pesticide residue levels below legal limits. Examples of such treatments include fractionation by means of distillation or removal by treatment with activated carbon; the treatment method always has to be validated. 2.011 husks By-products which are released during the de-shelling of dried beans of the cocoa tree, Theobroma cocoa L. Processing aids used during treatment and ing *) Activated carbon Bleaching earth Citric acid (C6H8O7) Hexane (C6H14) Perlite (Dicalite) Phosphoric acid (H3PO4) Potassium carbonate (K2CO3) Sodium hydroxide (NaOH) Sulfuric acid (H2SO4) Water (steam) *) For the ing aids used in production it must be demonstrated by way of a hazards analysis that the unintentional but technically unavoidable presence of residues of these ing aids or their derivatives in the end product has no detrimental effects on animal health, human health or the environment and no technological effect at all on the end product. Attention should also be paid in carrying out the analysis to the hazards of overdosage of ing aids and the presence of contaminants in the ing aids used. In the event of use as a feed additive then the above does not apply and there should be compliance with the applicable community legislation and the compatible national legislation. 2 / 17
Global Process diagram industry Start 1. Cultivation 2. Harvesting 3. 4. & 5. 6. Processing 7. 8. End of products 3 / 17
Detail 1 Process diagram industry Start Pesticides Herbicides Fungicides 1. Cultivation of cocoaplants Fertilizer 2.1 Harvesting pods 2.2 Fermentation Fuel 2.3.1 Drying (direct) 2.3.2 Drying (sun) Dried cocoabeans 2.4 Bagging up 3. A 4 / 17
Detail 2 Process diagram industry A 4.1 Bulk storage (outside EU) Pesticides (e.g. fosfine, methylbromine) 4.2 Fumigation 4.3 (across the border) 4.4 5. to factory 6.1 ing by pressing 6.2 ing by expelling B C 5 / 17
Detail 3 Process diagram industry Pressing industry B 6.1.1 Receipt 6.1.2 Cleaning Sand, stones, metal, glass, burlap, paper 6.1.6 Breaking 6.1.3 Deshelling nib (cocoabeans, deshelled) 6.1.7 Roasting / alkalization Steam, natural gas, water, alkalization agent husks 6.1.8 Grinding 6.1.4 Pelletizing / shredding mass 6.1.5 6.1.9 Sieving 1 6.1.10 Pressing butter cake Further ing human consumption 6 / 17
Detail 4 Process diagram ing industry Expelling industry C 6.2.1 Receipt 6.2.2 Cleaning Sand, stones, metal, glass, burlap, paper 6.2.3 Expelling expeller butter D expeller cake 2 6.2.4 6.2.5 Pelletizing Hexane 6.2.6 Extraction extraction butter E Steam, air 6.2.7 Desolventizing Hexane moisture 6.2.8 Pelletizing bean, extracted 3 7 / 17
Detail 5 Process diagram ing industry Degumming D E expeller butter extraction butter 6.3 Acid 6.4 Degumming Gums Water Dicalite 6.4 Filtration with dicalite butter, degummed F G 8 / 17
Detail 6 Process diagram ing industry Physically refining F 6.5.1 Store Steam 6.5.2 Distillative deacidification butter fatty acids Distillates from physical refining butter, physically refined 4 H 9 / 17
Detail 7 Process diagram ing industry Chemically refining G H 6.6.1 Store Sodium hydroxide 6.6.2 Soapformation free fatty acids Water Steam 6.6.3 Centrifuging / Separation butter, chemically refined Soaps of butter fatty acids I Sulfuric acid 6.6.4 Neutralizing Sodium sulfate Water 6.6.5 Centrifuging / Separtion Waste water butter acid oils from Chemical refining 5 10 / 17
Detail 8 Process diagram ing industry Bleaching and deodorizing I 6.7.1 Store Bleaching earth and possibly activated carbon 6.7.2 Bleaching Spent bleaching earth with possible activated carbon incl. soap remains and absorbed components Steam 6.7.3 Deodorizing dedistillates (untreated) butter, refined and deodorised 6.7.4 Validated treatment (to remove contaminants) e.g. fractionation by means of distillation and treatment with active carbon destillates (treated)* 6 * These treated deodestillates can oly be marketed under positive release for dioxin (see GMP+ BA4) 11 / 17
Detail 9 Process diagram ing industry Products 1 2 3 husks expeller (cake) bean, extracted 7.1 7.2 7.3 8.1 8.2 8.3 End of End of End of 4 5 6 butter fatty acid distillates from physical refining butter acid oils from chemical refining deodistillates (treated) 7.4 7.5 7.6 8.4 8.5 8.6 End of End of End of 12 / 17
Process step Hazard Risk assessment Information sources Reference in diagram Cultivation Harvesting and Preservation (at the primary company) Description Category Severity Likely occurence Antinutritional factors: Alkaloids Standards Suggestion for control measure Theobromine chemical high high GMP+ BA1 1 - Analyse further in the chain - Variety choice Antinutritional factors: Proteins Lectins chemical medium low 1 - Chemical treatment - Enzymatic treatment - Heat treatment Crop protection agents (Pesticides which are not permitted in the EU) Aldrin or Dieldrin chemical high low GMP+ BA1 1 - Crop registration Camphechlor (toxaphene) chemical high low GMP+ BA1 1 - Crop registration Chlordane chemical high low GMP+ BA1 1 - Crop registration DDT chemical high low GMP+ BA1 1 - Crop registration Endosulfan chemical high low GMP+ BA1 1 - Crop registration Endrin chemical high low GMP+ BA1 1 - Crop registration HCH: Alfa-isomer chemical high low GMP+ BA1 1 - Crop registration HCH: Beta-isomer chemical high low GMP+ BA1 1 - Crop registration HCH: Gamma-isomer (lindane) chemical high low GMP+ BA1 1 - Crop registration Heptachlor chemical high low GMP+ BA1 1 - Crop registration Hexachlorobenzene (HCB) chemical high low GMP+ BA1 1 - Crop registration Crop protection agents and biocides (permitted in the EU) Crop protection agents/biocides chemical high medium GMP+ BA1+BA3 1 - Controlled use of biocides - Supplier contract phytopharmaceuticals Salts Fluorine/Fluoride chemical high low GMP+ BA1 1 - Plot history Heavy metals Arsenic chemical high low GMP+ BA1 1 - Plot history Cadmium chemical high low GMP+ BA1 1 - Expert use of fertilisers - Plot history Mercury chemical high low GMP+ BA1 1 - Expert use of fertilisers - Plot history Lead chemical high low GMP+ BA1 1 - Expert use of fertilisers - Plot history Crop protection agents and biocides (permitted in the EU) Crop protection agents/biocides chemical high medium GMP+ BA1+BA3 2 - Analyse further in the chain - Controlled use of biocides Microbiological contamination Clostridia microbiological high low 2 - Training farmers on Good Agricultural Practices 13 / 17
Process step Hazard Risk assessment Information sources Reference in diagram Description Category Severity Likely occurence Standards Suggestion for control measure Enterobacteriaceae microbiological high low GMP+ BA1 2, 3, 4, 5 - (Locked) closed storage - Training farmers on Good Agricultural Practices Salmonella microbiological high medium GMP+ BA1 2, 3, 4 - (Locked) closed storage - Training farmers on Good Agricultural Practices Moulds and yeasts microbiological high medium GMP+ BA1 2 - Drying - Training farmers on Good Agricultural Practices Mycotoxin Aflatoxin B1 chemical high low GMP+ BA1 2, 3, 4 - Drying - Moisture analysis - Training farmers on Good Agricultural Practices Ochratoxin A chemical high low GMP+ BA1 2, 3, 4 - Drying - Moisture analysis - Training farmers on Good Agricultural Practices Foreign bodies (in the product) Glass physical high high 2, 3, 4 - (Locked) closed storage - Sieving / filtration later in the Wood (treated) physical high high GMP+ BA3 2, 3, 4 - (Locked) closed storage - Sieving / filtration later in the Plastics physical medium high GMP+ BA1 2, 3, 4 - (Locked) closed storage - Sieving / filtration later in the Metal particles physical high high 2, 3, 4 - (Locked) closed storage - Sieving / filtration later in the Packaging material: among others Polyethylene physical medium high GMP+ BA1+BA3 2, 3, 4 - (Locked) closed storage - Sieving / filtration later in the 14 / 17
Process step Hazard Risk assessment Information sources Reference in diagram Treatment / Processing Description Category Severity Likely occurence Standards Suggestion for control measure Sand, small stones physical medium high 2, 3, 4 - (Locked) closed storage - Sieving / filtration later in the Toxic substances Dioxins and dioxin-like PCBs chemical high medium GMP+ BA1+BA3 2.3 - Monitor complete combustion - Proper drying conditions - Safe fuels for the drying Hydrocarbons chemical high low GMP+ BA1 2, 3, 4, 5 - Feed/Food grade lubricants - Maintenance of machines and safe fuels Non dioxin-like PCBs chemical high low 2.3 - Monitor complete combustion - Safe fuels for the drying Polycyclic Aromatic Hydrocarbons (PAHs) chemical medium medium GMP+ BA1 2.3 - Monitor complete combustion - Proper drying conditions - Safe fuels for the drying Heavy metals (ash particles) chemical high low 2.3 - Safe fuels for the drying Antinutritional factors: Alkaloids Theobromine chemical high medium until high Crop protection agents and biocides (permitted in the EU) GMP+ BA1 6.1, 6.2 - Decontamination - Finished product analysis Crop protection agents/biocides chemical high low GMP+ BA1+BA3 6 - Finished product analysis (if using) Microbiological contamination Enterobacteriaceae microbiological high low GMP+ BA1 6.1, 6.2 - Finished product analysis Salmonella microbiological high medium GMP+ BA1 6.1, 6.2 - Finished product analysis Mycotoxin Aflatoxin B1 chemical high low GMP+ BA1 6.1, 6.2 - Finished product analysis Ochratoxin A chemical high low GMP+ BA1 6.1, 6.2 - Finished product analysis Foreign bodies (in the product) Glass physical high low 6 - Broken glass procedure available - Closed production system - Establish purchasing requirements - Sieving/filtration/wash Wood (treated) physical high high GMP+ BA3 6 - Closed production system - Establish purchasing requirements - Sieving/filtration/wash Plastics physical medium low GMP+ BA1 6 - Closed production system - Establish purchasing requirements - Sieving/filtration/wash 15 / 17
Process step Hazard Risk assessment Information sources Reference in diagram and Description Category Severity Likely occurence Standards Suggestion for control measure Metal particles physical high low 6 - Closed production system - Establish purchasing requirements - Metal detection - Sieving/filtration/wash Packaging material: among others Polyethylene physical medium low GMP+ BA1+BA3 6 - Closed production system - Establish purchasing requirements Sand, small stones physical medium low 6 - Closed production system - Establish purchasing requirements - Sieving/filtration/wash Toxic substances Dioxins and dioxin-like PCBs chemical high medium GMP+ BA1+BA3 6.1.7; 6.2.7, 6.5, 6.6 - Decontamination - Finished product analysis - Safe fuels for the drying Hydrocarbons chemical high low GMP+ BA1 6 - Closed production system - Feed/Food grade lubricants - Maintenance of machines and safe fuels Non dioxin-like PCBs chemical high low 6.1.7; 6.2.7, 6.5, 6.6 Polycyclic Aromatic Hydrocarbons (PAHs) chemical medium low GMP+ BA1 6.1.7; 6.2.7, 6.5, 6.6 Heavy metals (ash particles) chemical high low 6.1.7; 6.2.7, 6.5, 6.6 Foreign bodies (in the product) - Decontamination - Finished product analysis - Safe fuels for the drying - Finished product analysis - Safe fuels for the drying - Finished product analysis - Safe fuels for the drying Glass physical high low 7, 8 - (Locked) closed storage Wood (treated) physical high low GMP+ BA3 7, 8 - (Locked) closed storage Plastics physical medium low GMP+ BA1 7, 8 - (Locked) closed storage Metal particles physical high low 7, 8 - (Locked) closed storage Packaging material: among others Polyethylene physical medium low GMP+ BA1+BA3 7, 8 - (Locked) closed storage 16 / 17
Process step Hazard Risk assessment Information sources Reference in diagram Description Category Severity Likely occurence Standards Suggestion for control measure Sand, small stones physical medium low 7, 8 - (Locked) closed storage Toxic substances Hydrocarbons chemical high low GMP+ BA1 7, 8 - Feed/Food grade lubricants - Maintenance of machines and safe fuels 17 / 17