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CHAPTER 5a IMPROVEMENT OF A PROCESS FOR THE VITAMIN A FORTIFICATION OF PEANUT BUTTER FOR A SMALL COMPANY Gertrude M. Agustin 1 Alicia O. Lustre 2 Liza C. Tenorio 3 and Anna V.A. Resurreccion 4 1 Acting Division Chief, Food Development Center, 1632, Philippines 2 Co-Principal Investigator USAID-Peanut CRSP;Director, Food Development Center, 1632, Philippines 3 Research Specialist, Food Development Center, 1632, Philippines 4 Principal Investigator USAID-Peanut CRSP; Professor, University of Georgia, Griffin, 30223 Georgia, USA 111
ABSTRACT Studies were undertaken by the Food Development Center (FDC) to improve the direct addition method developed by Galvez et al. (2003) for incorporating a vitamin A fortificant to peanut butter that would suit the available facilities and existing process for peanut butter production of a small company, in order to transfer the technology. The goal was to encourage adoption by the company resulting in commercialization of the product. The studies looked into the effect of heat during the grinding process on the stability of the vitamin A fortificant by comparing the effects of adding the fortificant before and after the 2 nd grinding step on the percentage recovery of vitamin A. Product temperature before the grinding step is 58 o C and after the grinding step is 68 o C. The results of the study showed that changing the point of addition from before to after the 2 nd grinding step had no effect on vitamin A recovery. What appeared to be important was proper mixing of the vitamin A fortificant into the product. This was achieved by incorporation of the fortificant in staggered strokes, use of stabilizer as carrier for the small amount of fortificant that is added, and optimization of mixing time. When the vitamin A fortificant was added before the 2 nd grinding step, the average vitamin recovery was 87.95% and the variability was 5.92% at a mixing time of two minutes. At a mixing time of five minutes, the average vitamin A recovery was 90.13% and the variability was 7.08%. At a mixing time of 10 minutes, the average vitamin A recovery was 87.93% and the variability was 4.42%. When the vitamin A fortificant was added after the 2 nd grinding step, the vitamin A recovery was 90.08% and the variability was 12.63% after mixing for two minutes. At a mixing time of five minutes, the vitamin A recovery was 103.36% and the variability was 0.4%. When the FDC improved process was tested at the collaborator's plant, high vitamin A recoveries were initially obtained; 110.13% for two minutes and 109.89% for five minutes mixing. Consistent high recoveries however were not obtained. This variability could be due to the fact that the mixing process carried out manually and as the product is viscous, it is likely that the mixing strokes are not carried out with uniform efficiency between personnel. This possibility is being evaluated. In summary, the process for fortification is as follows: (1) Addition of the vitamin A fortificant after the one-time grinding of roasted peanuts and sugar, (2) Addition and manual mixing of the vitamin A fortificant to Myverol prior to incorporation to the peanut butter matrix, (3) Manual mixing of the mixture of vitamin A fortificant and stabilizer to peanut butter matrix for two minutes, (4) Rapid cooling of the fortified peanut butter in an ice water bath using ice packs in plastic containers to maintain the required 10 o C temperature, (5) Conditioning/tempering of the fortified peanut butter in a household refrigerator at a temperature range of 2 – 8 o C. The technology for the vitamin A fortification and stabilization of peanut butter was formally transferred to the small company in February 2007. The technology for the stabilization of peanut butter was readily adopted by the collaborator but the technology for vitamin A fortification was temporarily shelved for the following reasons: (a) Need to hire a technical personnel to oversee the addition/mixing of fortificant because the present manpower complement of the company do not have a technical 112
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United States Agency for Internatio
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VITAMIN A FORTIFICATION OF PEANUT B
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TABLE OF CONTENTS Page ACKNOWLEDGEM
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F. Statistical Analysis G. Technolo
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Study 1. Preliminary Verification o
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VII. REFERENCES 163 VIII. APPENDIX
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VIII. APPENDICES Appendix A. Risk A
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LIST OF TABLES Chapter 1. Vitamin A
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Chapter 4. Vitamin A Fortification
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Table 8.4 Physical evaluation (oil
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Chapter 5a. Improvement of a Proces
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CHAPTER 1 VITAMIN A FORTIFICATION O
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INTRODUCTION Physical and mental de
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variety from Vietnam, provided by t
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Two fortificants were used in this
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the first grinding, and (b) in the
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Table 1.2 Percent vitamin A recover
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CONCLUSIONS The study showed that p
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APPENDIX A COLLABORATION AND CONFID
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Proposed by: The Food Development C
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C. FDC and UPCHE shall return all c
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Name_______________________________
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ABSTRACT Experiments were conducted
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INTRODUCTION Vitamin A is an essent
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available for addition to foods mai
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The study was carried out in three
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Prepare dyed oil by adding ½ teasp
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until no trace of the fortificant w
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The vitamin A content present in th
Page 62 and 63: Weigh required amounts of premix an
Page 64 and 65: used. From each production batch, o
Page 66 and 67: Preparation of fortified peanut but
Page 68 and 69: Table 2.5 Effect on vitamin A recov
Page 70 and 71: On the other hand, fortified peanut
Page 72 and 73: Table 2.9 Effect on vitamin A recov
Page 74 and 75: REFERENCES AOAC. 1995. Official Met
Page 76 and 77: Procedural Guideline for the Vitami
Page 78 and 79: (Note: Recommended mixing time of t
Page 80 and 81: (1) Prepare plain peanut butter as
Page 82 and 83: CHAPTER 3 VITAMIN A FORTIFICATION O
Page 84 and 85: INTRODUCTION Vitamin A deficiency c
Page 86 and 87: Table 3.1 Experimental design for t
Page 88 and 89: Pre-heat roaster to 140°C Fill roa
Page 90 and 91: Technology Transfer The technology
Page 92 and 93: Table 3.3 Analysis of Variance (ANO
Page 94 and 95: (1983) as cited by Solon et al. (19
Page 96 and 97: Table 3.6 Analysis of the individua
Page 98 and 99: Hinds, M.J., Chinnan, M.S. and Beuc
Page 100 and 101: ABSTRACT Chocolate-peanut spread wa
Page 102 and 103: OBJECTIVES This study was undertake
Page 104 and 105: Pre-heat roaster to 140°C Fill roa
Page 106 and 107: µgRE/g = µg/g ß-carotene x 0.3
Page 108 and 109: Table 4.3 Analysis of Variance (ANO
Page 110 and 111: Technology Transfer Results of the
Page 114 and 115: ackground, (b) Need to purchase add
Page 116 and 117: METHODS For this project, the vitam
Page 118 and 119: Study 2. Preliminary Verification o
Page 120 and 121: Study 3. Establishment of Mixing Ti
Page 122 and 123: Study 2. Validation of the Results
Page 124 and 125: Table 5a.1 Evaluation of available
Page 126 and 127: Process Flow Observation Evaluation
Page 128 and 129: Table 5a.4 Vitamin A content and %
Page 130 and 131: When the fortificant and stabilizer
Page 132 and 133: Since the collaborator decided to u
Page 134 and 135: (c) Processing area is too small su
Page 136 and 137: APPENDIX A PROCESS FLOW FOR THE STA
Page 138 and 139: (Note: The use of a wooden rod to p
Page 140 and 141: APPENDIX B PROCESS FLOW FOR THE VIT
Page 142 and 143: (Note: During the conditioning/temp
Page 144 and 145: CHAPTER 5b IMPROVEMENT OF A PROCESS
Page 146 and 147: INTRODUCTION Vitamin A deficiency i
Page 148 and 149: the collaborator at Vitachem Indust
Page 150 and 151: Four volumes of ~38.81 kg peanut bu
Page 152 and 153: 4 parts of ~38.81 Kg peanut butter
Page 154 and 155: Study 3. Effect of Incorporating th
Page 156 and 157: Study 4. Validation of the Recovery
Page 158 and 159: Table 5b.1 Vitamin A content and vi
Page 160 and 161: Study 2. Effect of incorporating th
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Table 5b.4. Vitamin A content, % vi
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CONCLUSIONS Based on the results of
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APPENDIX A PROCEDURAL GUIDELINE FOR
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6. When all four (4) volumes of pea
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Step No. Process Flow 17 Put label
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ABSTRACT This document describes th
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The process for the Vitamin A forti
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5. Storage of water supply: Water i
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column of numbers 2.1 to 2.3 of the
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2. List of Personnel Who Attended I
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6. Handling of raw materials: The P
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CONTROL NO. VIII. EXCLUSION OF PEST
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Appendix A (Name of Company) STANDA
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Date of Inspection: _______________
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Appendix 3 Record No. 1 continued
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Materials needed: Appendix D (Name
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Date: __________ Appendix E (Name o
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P2 V2 X1 = -------- P1 (1%) (3.78 K
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Materials Needed: Appendix G (Name
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Date: __________ Water Tank No. ___
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Date of Inspection: _______________
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Appendix L (Name of Company) EQUIPM
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Appendix M-2 (Name of Company) WEEK
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Appendix O (Name of Company) LIST O
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Worker’s Name Appendix Q (Name of
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Appendix S (Name of Company) CLEANI
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Appendix U (Name of Company) CLEANI
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Appendix W (Name of Company) CLEANI
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Name of worker Medical certificate
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CHAPTER 7 DEVELOPMENT OF A GENERIC
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INTRODUCTION Development of a gener
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2. HACCP is not mandatory As HACCP
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GENERIC HACCP PLAN FOR VITAMIN A FO
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3, 4 Section 5. Process Flow Diagra
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5.3 Preparation of Fortified Peanut
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STEP DETAILED DESCRIPTION 4. DRY BL
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6.3 Preparation of Fortified Peanut
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(1) Process Step 2. STORAGE OF RAW
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(1) Process Step 16.WEIGHING OF FOR
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(1) Process Step 24. MANUAL FILLING
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Process Step 5. COOLING None 6. DE-
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Process Step 19. WEIGHING AND PACKI
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Section 9. HACCP Plan Form 11 Firm
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Section 10. Validation of the HACCP
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RECORDS FOR HAZARD ANALYSIS CRITICA
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(Name of Company) VITAMIN A FORTIFI
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(Name of company) VITAMIN A FORTIFI
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Appendix A RISK ASSESSMENT MODEL FO
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5. Process Flow Diagram - This is t
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Appendix C RECOMMENDED PRE-REQUISIT
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CHAPTER 8 OBTAINING SANGKAP PINOY S
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OBJECTIVES The general objective wa
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different accelerated temperatures
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Table 8.3 Visual evaluation of the
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Table 8.6 Development of rancid odo
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Based on the above results, the pre
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NOTE ON ADOPTION OF THE IMPROVED PR
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INTRODUCTION Food fortification has
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Table 1 Criteria used in the identi
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REFERENCES Agustin, G.M., Lustre, A
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PROPOSAL FOR R&D COLLABORATION ____
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APPENDIX B SIGNING OF MEMORANDUM OF
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APPENDIX C BUILDING AND FACILITIES
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APPENDIX D SANITATION UPDATES 287
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STANDARD SANITATION OPERATING PPROC
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E. PEST CONTROL Procedure Monitorin
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TRAINING ON THE PROCESSING OF STABI
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Training on the Processing of Stabi
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