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INTRODUCTION Development of a generic HACCP plan was one of the outputs of the project on the development of a HACCP Based Quality Control Program for Vitamin A Fortified Peanut Butter. The project aimed to ensure that vitamin A peanut butter would be safe and consistent in quality per production batch that would lead to accreditation by the Department of Health’s Sangkap Pinoy Seal Program. The generic HACCP plan for vitamin A fortified peanut butter was developed by FDC to serve as the industry collaborator’s guide to ensure product safety during manufacture and that levels of vitamin A consistently meet the requirements of local regulations. OBJECTIVES The objective of the study was to develop a generic Hazard Analysis Critical Control Point (HACCP) Plan to help companies produce vitamin A fortified peanut butter that is safe and which consistently meets the requirements for vitamin A fortification of foods by the Department of Health. Preliminary Activity METHODS Observations were made on the process for vitamin A addition in peanut butter manufacture. This was carried out at the plant of an industry collaborator which received the technology for vitamin A fortified peanut butter developed separately by FDC in this project. Creation of the FDC HACCP Plan Team After several plant visits and interviews, FDC created its HACCP Plan Team which carried out the analysis of hazards and other tasks required in the development of a HACCP Plan. The HACCP Plan Team was led by Edith M. San Juan, Supervising Research Specialist and was supported by Jocelyn M. Sales, Division Chief, Fe R. Vito, Supervising Research Specialist, and Alberto R. Cariso Jr., Division Chief. Dr. Alicia O. Lustre, Director, FDC-NFA, reviewed the analysis and the developed Plan. Hazard Identification and Ranking Potential hazards were identified based on scientific literature and results of FDC’s applied research or experience. Market regulations also provided a clue to potential hazards. The identified hazards were evaluated and ranked as to severity and likelihood of occurrence using the risk ranking model of the Netherlands Product Board Animal Feed (PDV, 2001) shown in Appendix A. The rank of 221
the identified hazard determined the type of control measure that would be necessary to control the hazard. Determination of critical control points (CCPs) CCPs were identified using the Codex CCP Decision Table. CCPs are points in the process where control measures should be adapted to prevent or eliminate a food safety hazard or reduce it to an acceptable level. Development of the HACCP Plan Form This form identifies the CCPs, prescribes the control measures to be adopted at each CCP, the critical limits for each control measure, corrective actions to be taken when needed, monitoring and recording procedures to ensure that all control measures are properly implemented and procedures for independent verification that the Plan is implemented as prescribed and documented. The contents were developed by the HACCP Team. Contents of the HACCP Plan This HACCP Plan has ten sections, the definitions of which are described in Appendix B. The ten sections are: (1) the pre-requisite requirements, (2) scope, (3) product description and intended use, (4) initial food safety objectives (FSOs), (5) process flow diagram, (6) process description, (7) hazard analysis, (8) critical control point determination, (9) HACCP Plan form development, and (10) HACCP Plan verification. The approaches used for each section were based on recommendations of the Codex Alimentarius Commission (1997), for sections 1, 2, 3, 5, 7, 8, 9 and 10; the Meat Industry Association (MIA, 1999) and the Ministry of Agriculture and Forestry (MAF, 1999) of New Zealand for section 4; Price (1996) for section 6; and the Netherlands Product Board Animal Feed (PDV, 2001) for the ranking of hazards. Technology Transfer A one-day seminar on HACCP was conducted by FDC on March 10, 2000 to orient the HACCP Team of Newborn Food Products, Inc. on the principles of HACCP and the steps for its implementation. The HACCP Team of the collaborator was composed of five personnel from the management, production and research. Reasons for Non-Adoption of the SSOP by Newborn Food Products, Inc. 1. Processing plant failed to comply with GMP requirements Due to non-compliance to GMP requirements, the company was unable to adopt the HACCP Plan developed for their product. Several plant deficiencies remained uncorrected and the developed SSOP was still not implemented. 222
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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
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Preparation of fortified peanut but
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Table 2.5 Effect on vitamin A recov
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On the other hand, fortified peanut
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Table 2.9 Effect on vitamin A recov
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REFERENCES AOAC. 1995. Official Met
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Procedural Guideline for the Vitami
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(Note: Recommended mixing time of t
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(1) Prepare plain peanut butter as
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CHAPTER 3 VITAMIN A FORTIFICATION O
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INTRODUCTION Vitamin A deficiency c
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Table 3.1 Experimental design for t
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Pre-heat roaster to 140°C Fill roa
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Technology Transfer The technology
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Table 3.3 Analysis of Variance (ANO
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(1983) as cited by Solon et al. (19
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Table 3.6 Analysis of the individua
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Hinds, M.J., Chinnan, M.S. and Beuc
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ABSTRACT Chocolate-peanut spread wa
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OBJECTIVES This study was undertake
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Pre-heat roaster to 140°C Fill roa
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µgRE/g = µg/g ß-carotene x 0.3
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Table 4.3 Analysis of Variance (ANO
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Technology Transfer Results of the
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CHAPTER 5a IMPROVEMENT OF A PROCESS
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ackground, (b) Need to purchase add
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METHODS For this project, the vitam
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Study 2. Preliminary Verification o
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Study 3. Establishment of Mixing Ti
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Study 2. Validation of the Results
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Table 5a.1 Evaluation of available
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Process Flow Observation Evaluation
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Table 5a.4 Vitamin A content and %
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When the fortificant and stabilizer
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Since the collaborator decided to u
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(c) Processing area is too small su
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APPENDIX A PROCESS FLOW FOR THE STA
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(Note: The use of a wooden rod to p
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APPENDIX B PROCESS FLOW FOR THE VIT
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(Note: During the conditioning/temp
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CHAPTER 5b IMPROVEMENT OF A PROCESS
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INTRODUCTION Vitamin A deficiency i
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the collaborator at Vitachem Indust
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Four volumes of ~38.81 kg peanut bu
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4 parts of ~38.81 Kg peanut butter
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Study 3. Effect of Incorporating th
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Study 4. Validation of the Recovery
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Table 5b.1 Vitamin A content and vi
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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
Page 172 and 173: ABSTRACT This document describes th
Page 174 and 175: The process for the Vitamin A forti
Page 176 and 177: 5. Storage of water supply: Water i
Page 178 and 179: column of numbers 2.1 to 2.3 of the
Page 180 and 181: 2. List of Personnel Who Attended I
Page 182 and 183: 6. Handling of raw materials: The P
Page 184 and 185: CONTROL NO. VIII. EXCLUSION OF PEST
Page 186 and 187: Appendix A (Name of Company) STANDA
Page 188 and 189: Date of Inspection: _______________
Page 190 and 191: Appendix 3 Record No. 1 continued
Page 192 and 193: Materials needed: Appendix D (Name
Page 194 and 195: Date: __________ Appendix E (Name o
Page 196 and 197: P2 V2 X1 = -------- P1 (1%) (3.78 K
Page 198 and 199: Materials Needed: Appendix G (Name
Page 200 and 201: Date: __________ Water Tank No. ___
Page 202 and 203: Date of Inspection: _______________
Page 204 and 205: Appendix L (Name of Company) EQUIPM
Page 206 and 207: Appendix M-2 (Name of Company) WEEK
Page 208 and 209: Appendix O (Name of Company) LIST O
Page 210 and 211: Worker’s Name Appendix Q (Name of
Page 212 and 213: Appendix S (Name of Company) CLEANI
Page 214 and 215: Appendix U (Name of Company) CLEANI
Page 216 and 217: Appendix W (Name of Company) CLEANI
Page 218 and 219: Name of worker Medical certificate
Page 220 and 221: CHAPTER 7 DEVELOPMENT OF A GENERIC
Page 224 and 225: 2. HACCP is not mandatory As HACCP
Page 226 and 227: GENERIC HACCP PLAN FOR VITAMIN A FO
Page 228 and 229: 3, 4 Section 5. Process Flow Diagra
Page 230 and 231: 5.3 Preparation of Fortified Peanut
Page 232 and 233: STEP DETAILED DESCRIPTION 4. DRY BL
Page 234 and 235: 6.3 Preparation of Fortified Peanut
Page 236 and 237: (1) Process Step 2. STORAGE OF RAW
Page 238 and 239: (1) Process Step 16.WEIGHING OF FOR
Page 240 and 241: (1) Process Step 24. MANUAL FILLING
Page 242 and 243: Process Step 5. COOLING None 6. DE-
Page 244 and 245: Process Step 19. WEIGHING AND PACKI
Page 246 and 247: Section 9. HACCP Plan Form 11 Firm
Page 248 and 249: Section 10. Validation of the HACCP
Page 250 and 251: RECORDS FOR HAZARD ANALYSIS CRITICA
Page 252 and 253: (Name of Company) VITAMIN A FORTIFI
Page 254 and 255: (Name of company) VITAMIN A FORTIFI
Page 256 and 257: Appendix A RISK ASSESSMENT MODEL FO
Page 258 and 259: 5. Process Flow Diagram - This is t
Page 260 and 261: Appendix C RECOMMENDED PRE-REQUISIT
Page 262 and 263: CHAPTER 8 OBTAINING SANGKAP PINOY S
Page 264 and 265: OBJECTIVES The general objective wa
Page 266 and 267: different accelerated temperatures
Page 268 and 269: Table 8.3 Visual evaluation of the
Page 270 and 271: 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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