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GENERIC HACCP PLAN FOR VITAMIN A FORTIFIED PEANUT BUTTER Section 1. Pre-requisite Requirements Prior to implementing a HACCP Plan, pre-requisite programs for Good Manufacturing Practices and Sanitation should be documented and effectively implemented. These programs can be based on Codex Principles of Food Hygiene and appropriate Codex Codes of Practice (CAC, 1997). A list of recommended pre-requisites of the Ministry of Agriculture and Forestry–Food Assurance Group of the New Zealand (MAF, 1999) is shown in Appendix C as an example. In the United States, the pre-requisite program for HACCP is the Sanitation Standard Operating Procedure (USFDA, 1997. 21 CFR 123; USFDA, 2001. 21 CFR 120), the components of which are listed in Appendix D. Section 2. Scope of the HACCP Plan This Plan applies to controlling biological, chemical and physical hazards to acceptable levels from receipt of raw shelled peanuts and other raw materials, production of the premix, addition of vitamin A to the peanut butter and storage and transport of the product. Section 3. Product Description and Intended Use 3.1 Product name Vitamin A Fortified Peanut Butter 3.2 Important product characteristics, composition, physical/chemical structure, processing treatments Vitamin A fortified peanut butter has a deep brown color and a fine smooth texture, with a characteristic roasted peanut odor and flavor and a moderately sweet taste. The product has a vitamin A content of 8.5 – 11.6 μg retinol/g peanut butter or 340 – 464 μg retinol for a serving size of 40 g. The product should meet minimum requirements for physical, sensory, chemical, and microbiological qualities of regulatory agencies, and buyers. The product is produced by mixing plain peanut butter with a premix consisting of peanut butter with added vitamin A. 3.3 Packaging The product is packed in glass jars with metal caps or in plastic jars and caps. 3.4 Shelf life and storage requirements At ambient temperatures* of 30°C and normal conditions of handling, the product has a shelf life of 6 months. (*Philippine ambient conditions 1 ) 1 Information taken from the shelf life study conducted on the product as per PCRSP Final Report for Project 3.2.13C (Obtaining Sangkap Pinoy Seal for Vitamin A Fortified Peanut Butter for the Department of Health). 225
Section 3 (continued) 3.5 Method of distribution The product is distributed at ambient conditions all over the country at a temperature of 30°C. It is unlikely to be stored for long periods of time. 3.6 Intended use Ready-to-eat or as an ingredient in food preparations. 3.7 Intended consumers The general public. Section 4. Food Safety Objectives (FSOs) 2 FSO1: To ensure that the correct amount of vitamin A fortificant is present in the peanut butter premix and in the vitamin A fortified peanut butter. The peanut butter premix, is peanut butter to which a known amount of vitamin A fortificant has been added at levels that will ensure that the right amount of vitamin A is in the final fortified product after incorporation of the premix. Basis: Addition of excessive amounts of the fortificant to the premix or of excessive amounts of premix at the final mixing stage, could make the product toxic. ______________ 2 This format is taken from the Meat Industry Association of New Zealand (MIA, 1999). 226
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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
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ABSTRACT This document describes th
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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 222 and 223: INTRODUCTION Development of a gener
Page 224 and 225: 2. HACCP is not mandatory As HACCP
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
Page 272 and 273: Based on the above results, the pre
Page 274 and 275: 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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