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METHODS For this project, the vitamin A fortificant used was a microencapsulated vitamin A palmitate obtained from BASF Philippines (Carmelray Park, Canlubang, Laguna). It was contained in a laminated foil pouch at 50 g per pack. The vitamin A fortificant was described as a free flowing, light yellow powder consisting of spherical particles that contain vitamin A palmitate in droplets of 1-2 µm embedded in a matrix of gum arabic (E 414) and sucrose, coated with starch, t-butyl-hydroxytoluene (BHT, E321) and sodium ascorbate (E301) as antioxidants and tricalcium phosphate (E-341) as an anti-caking product (BASF, 2005). The stabilizer used in this project was Myverol 18-04, a distilled monoglyceride derived from fully hydrogenated fats and oils. It was purchased at BNC Ingredients Corporation (252 Sen. Gil Puyat Avenue, Makati City) and C.K. Baker (EDSA Muñoz, Quezon City). The study was undertaken in three phases as follows: (1) Preliminary activities for technology transfer, (2) Standardization of the process at FDC considering the collaborating industry’s facilities, and (3) Standardization of the process at the collaborator's plant. Preliminary Activities for Technology Transfer A plant visit and a seminar on Good Manufacturing Practices (GMP) were conducted at the collaborator's plant as preliminary activities for the transfer of a technology for the vitamin A fortification of a stabilized peanut butter. The former was conducted to evaluate the collaborator's existing process for peanut butter production and to identify suitability of its available facilities for vitamin A fortification. The latter was conducted to create awareness among the production workers on the importance of GMP. Standardization of the Process Considering Collaborator's Facilities Three studies were conducted at FDC to improve the direct addition method developed by Galvez et al. (2003) for incorporating the vitamin A fortificant to peanut butter. Modification of the process was necessary as the collaborator's process for the production of peanut butter was a one-time grinding step, thus, addition of the fortificant can only be done after the grinding step. In the direct addition method developed by Galvez et al. (2003), the vitamin A fortificant was added to the peanut butter matrix before the 2 nd grinding step in a colloid mill. The three studies conducted were as follows: Study 1. Preliminary Verification of the Direct Addition Procedure Developed by PCRSP for the Vitamin A Fortification of Peanut Butter This study was conducted to verify if the same % recovery of vitamin A achieved in the direct addition method for vitamin A fortification developed by Galvez et al. (2003) can be replicated using conditions existing in the industry collaborator’s plant and using the new type of available stabilizer in the market. Procedure for the preparation of fortified stabilized peanut butter adapted from Galvez et al. (2003). Fortified stabilized peanut butter was prepared following the direct addition procedure of Galvez et al. (2003) shown in Fig. 5a.1. The vitamin A fortificant was added at a level of 0.3678 g per 6 Kg peanut butter while the level of stabilizer was 0.8% Myverol (w/w combined weight of roasted peanuts 115
and sugar). The fortified stabilized product was evaluated for vitamin A recovery, dispersion and for presence of oil separation. Method of sampling and analysis. One sample each of fortified peanut butter was collected at the start, middle and end of the filling operations in plastic bottles, for vitamin A analysis. A 10 g sample of the vitamin A fortificant was taken from the 5 Kg capacity aluminum can and transferred to a 100 mL capacity aluminum can, for vitamin A analysis. The vitamin A content of the fortified product and vitamin A fortificant were analyzed at the FDC Chemistry Laboratory using AOAC (1995) Official Methods of Analysis # 974-29. Vitamin A recovery and percentage variability. Using the data on vitamin A content, the % vitamin A recovery and % variability of replicate samples were calculated using the formula: % Recovery of vitamin A = Amount of vitamin A found (μgRE/g) x 100 Amount of vitamin A added (μgRE/g) % Variability = Standard deviation of vitamin A in replicate samples__ x 100 Average vitamin A content found in replicate samples Blanched peanuts stored in freezer (-9 to -12°C) for 4 months Roasting of blanched peanuts to light brown color in a pan under medium heat Chopping of roasted peanuts in a silent cutter (Model FC-380-3H, Fujimak, Japan) Addition and mixing of sugar (20% w/w peanuts) to chopped peanuts 1 st grinding of chopped peanuts and sugar in a colloid mill at No. 2 setting Addition and manual mixing of vitamin A fortificant with stabilizer (0.8% w/w roasted peanuts and sugar) for 5 min 2 nd grinding of mixture of peanut butter, vitamin A fortificant and stabilizer in a colloid mill at No. 0 setting Manual filling of fortified peanut butter in 8 oz glass bottles Cooling of fortified peanut butter in an ice-water bath (10°C) for two hrs Conditioning/tempering of cooled fortified peanut butter in a refrigerator (2 – 8°C) for 24 - 48 hrs Fig. 5a.1 Schematic diagram of the direct addition method for incorporating the vitamin A fortificant to peanut butter adapted from Galvez et al. (2003) 116
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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
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Weigh required amounts of premix an
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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 112 and 113: CHAPTER 5a IMPROVEMENT OF A PROCESS
Page 114 and 115: ackground, (b) Need to purchase add
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
Page 162 and 163: Table 5b.4. Vitamin A content, % vi
Page 164 and 165: 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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