See discussions, stats, and author profiles for this publication at: https://www.researchgate.net/publication/270272480 Application of ISO 22000 in comparison with HACCP on industrial processing of milk chocolate Article  in  International Food Research Journal · January 2013 CITATIONS READS 5 2,347 5 authors, including: Emmanuel Ohene Afoakwa Henry Mensah-Brown University of Ghana University of Ghana 141 PUBLICATIONS   2,056 CITATIONS    22 PUBLICATIONS   77 CITATIONS    SEE PROFILE SEE PROFILE Some of the authors of this publication are also working on these related projects: VLIR TEAM COCOA PROJECT View project FISH SMOKING SYSTEMS IN GHANA: IMPLICATIONS ON FOOD SAFETY AND NUTRITION View project All content following this page was uploaded by Emmanuel Ohene Afoakwa on 31 December 2014. The user has requested enhancement of the downloaded file. International Food Research Journal 20(4): 1771-1781 (2013) Journal homepage: http://www.ifrj.upm.edu.my Application of ISO 22000 in comparison with HACCP on industrial processing of milk chocolate 1*Afoakwa, E. O, 2Mensah-Brown, H., 1Crentsil, G. K., 3Frimpong, K. and 3Asante, F. 1Department of Nutrition & Food Science, University of Ghana, Legon-Accra, Ghana 2Department of Food Process Engineering, University of Ghana, Legon-Accra, Ghana 3Cocoa Processing Company of Ghana, P. O. Box 40, Tema, Ghana Article history Abstract Received: 23 January 2013 Hazard analysis was conducted to identify critical control points (CCPs) during cocoa processing Received in revised form: and milk chocolate manufacture and applied into a hazard analysis and critical control point 10 March 2013 (HACCP) plan. During the process, the different biological, physical and chemical hazards Accepted: 13 March 2013 identified at each processing stage in the hazard analysis worksheet were incorporated into the HACCP plan to assess the risks associated with the processes. Physical hazards such as metals, Keywords stones, fibres, plastics and papers; chemical hazards such as pesticide residues, mycotoxins and heavy metals; and microbiological hazards such as Staphyloccous aureus, coliforms, Food safety Salmonella, Aspergillus and Penicillium were identified. ISO 22000 analysis was conducted Cocoa for the determination of some pre-requisite programmes (PrPs) during the chocolate processing Chocolate Critical control point and compared with the HACCP system. The ISO 22000 Analysis worksheet reduced the CCPs HACCP for both cocoa processing and chocolate manufacture due to the elimination of the pre-requisite ISO 22000 programmes (PrPs). Monitoring systems were established for the CCPs identified and these Pre-requisite programmes included preventive measures, critical limits, corrective actions, assignment of responsibilities and verification procedures. The incorporation of PrPs in the ISO 22000 made the system simple, more manageable and effective since a smaller number of CCPs were obtained. © All Rights Reserved Introduction system is capable of accommodating change, such as advances in equipment design, processing procedures Food safety is linked with food-borne hazards or technological developments (Codex Alimentarius present in food at the point of consumption. Since Commission, 1999). Its concept permits a systematic food safety hazards can occur at any stage in the food approach to the identification of hazards and an chain it is essential that adequate control measures be assessment of the likelihood of their occurrence put in place to avoid or minimize food safety hazards during the manufacture, distribution and use of a (Prati and McIntyre, 2004). ISO 22000 is a standard food product, and defines measures for their control developed by the International Organization for (van Schothorst, 2004). The resulting HACCP plan Standardization (ISO) as a requirement for the food can be integrated in a more general quality and safety chain organization to enhance food safety (Blank, assurance plan. 2006). It was developed as an improvement to ISO Within the last 20 years, chocolate products have 9000. In comparison with ISO 9000, the standard been the cause of many salmonellosis outbreaks is more procedure-orientated than principle-based. involving mainly children (Cordier, 1994). The main The ISO 22000 international standard specifies the reason has been the very low levels of Salmonella requirements for a food safety management system. It found in such contaminated chocolate products. involves the elements of interactive communication, Additionally, chocolate may contain other spoilage system management, pre-requisite programmes organisms such as yeasts and molds, Staphylococcus and HACCP principles. According to ISO (2010), aureus and other coliforms. Molds may spoil ISO 22000 can be applied independently of other chocolate by hydrolyzing lipids present to fatty management system standards or integrated with acids. This results in the rancid taste of chocolate. It existing management system requirements. is therefore necessary to take preventive measures The Hazard Analysis and Critical Control Points during processing to avoid re-contamination of the (HACCP) system is science based and systematic. product after the roasting step which represents It identifies specific hazards and measures for their the only barrier for Salmonella and other spoilage control to ensure the safety of food. Any HACCP microorganisms (Case, 2010). HACCP systems are *Corresponding author. Email: eoafoakwa@gmail.com / eafoakwa@ug.edu.gh Tel: +233 (0) 244 685893 1772 Afoakwa et al./IFRJ 20(4):1771-1781 therefore designed to prevent re-contamination. The current systems. Most importantly according to Llano control of hazards in chocolate processing is essential (2011) it; since the consequences of its failure can be illustrated i. Focuses on identifying and preventing by a number of serious and high profile incidents and hazards from contaminating foods. recalls over the past decade. Such incidents can cause ii. Permits more efficient and effective illness, injury or in the most severe cases, death to the government oversight, primarily because the record consumer (Burndred, 2009). keeping allows investigators to see how well a firm is complying with food safety laws over a period rather Hazard Analysis and Critical Control Points than how well it is doing on a given day. (HACCP) iii. Places responsibility for ensuring food The basis of HACCP are that it is a process control safety appropriately on the food manufacturer or rather than a product control procedure and that it distributor. focuses on controlling steps in the processing system iv. Helps food companies compete more that are critical to consumer health (Arvanitoyannis effectively in the world market. and Varzakas, 2008). v. Reduces barriers to international trade. HACCP is a structured approach to the Also the advantages of HACCP according to identification, assessment of risk (likelihood of Whitehead and Orris (1995) include; occurrence and severity), and control of hazards i. The HACCP system is capable of associated with food production process or practice. accommodating change, such as advances in It addresses the root causes of food safety problems in equipment design, processing procedures or production, storage, transportation, and is preventative technological developments. (FDA, 1994). It aims to identify possible problems ii. Provides a more effective use of resources before they occur and establish control measures at and more timely response to food safety problems. stages in the production process that are critical to iii. The HACCP system is compatible with the product safety. One of the purposes of HACCP is to implementation of quality management systems, such design safety into the process, thereby reducing the as the International Organization for Standardization’s need for extensive microbiological testing of inline ISO 9000 series. samples and finished products (Silliker, 1995). There can hardly be HACCP without Good ISO 22000 Manufacturing or Management Practices (GMP). ISO 22000 is a standard developed by the GMP is a description of all the steps in a processing International Organization for Standardization as facility, while HACCP is a documentation that the a requirement for the food chain organization to steps important to consumer health are under control enhance food safety (Blank, 2006). The ISO 22000 (Arvanitoyannis and Varzakas, 2009). Sanitation international standard specifies the requirements for a standard operating procedures (SSOPs) are also a food safety management system. This standard further needed pre-requisite to HACCP. Pre-requisites are clarifies the concept of pre-requisite programmes advisory not mandatory. GMPs differ from HACCP which are divided into two sub-categories: in a number of ways. First, they are not designed to infrastructure and maintenance programmes and control specific hazards. Second, they do not provide operational pre-requisite programmes. Infrastructure methods for monitoring hazards and third, they and maintenance programmes are used to address do not require specific recordkeeping procedures basic requirements of food hygiene, and accepted (Arvanitoyannis and Varzakas, 2008). good practice of a more permanent nature, whereas operational pre-requisite programmes are used to HACCP principles control or reduce the impact of identified food safety The HACCP principles are clearly defined and hazards in the product or the processing environment they are considered to be one of the most useful tools (Faergemand and Jersperson, 2004). for proactive identification and control of hazards in foods. According to the Codex Alimentarius Advantages of ISO 22000 Commission (1999), the HACCP system consists of According to the National Sanitation Foundation seven principles which have been well outlined by (NSF) (2004), and Arvanitoyannis and Varzakas Arvanitoyannis and Varzakas (2009). (2008), the main advantages of ISO 22000 include: i. Allows the organisation within the food chain Advantages of HACCP to demonstrate their commitment to food safety. HACCP offers a number of advantages over ii. Enables the optimum distribution of resources Afoakwa et al./IFRJ 20(4):1771-1781 1773 inside the food chain organization. Table 1. Grade standards of cocoa iii. Improves the effectiveness of internal and Grade Bean count per 100 g Mouldy Slaty Defective Beans (germinated, insect-damaged etc.) external communication between suppliers, clients, 1A ≤ 100 3% 3% 2.5% authorities and other authorities involved. 1B 101 – 200 3% 3% 2.5% iv. Focuses on the pre-requisite programmes, 2A ≤ 100 4% 8% 5% conditions and hygiene measures, planning of 2B 101 – 200 4% 8% 5% preventive actions with the aim of eliminating any Substandard > 120 > 4% > 8% > 5% possible failures. Source: (Afoakwa, 2010) v. Allows for better documentation. vi. It improves the management processes and provision of resources and visual operations. vii. There is the ability to show control of known food hazards Hazards associated with chocolate processing Hazards associated with foods may be defined as anything related to the food that might cause harm to the consumer. According to ISO 22000, a food safety hazards is a biological, chemical or physical agent in food or condition of food with the potential to cause an adverse health effect (Burndred, 2009). Figure 1. An example of decision tree to identify CCPs (Codex Physical hazards Alimentarius, 1999) (Answer questions in sequence) Physical hazards are foreign bodies that are hard *Proceed to the next identified hazard in the described process**Acceptable and unacceptable levels needed to be determined within the overall and/or sharp. They may cause physical injury such objectives in identifying the CCPs of the HACCP plan as cuts to the mouth, throat or digestive system or Microbiological hazards may cause choking. Foreign bodies can be defined Microbial hazards in cocoa processing and as matter that is present in a food but which whether chocolate manufacture are mainly present during the of intrinsic or extrinsic origin is undesirable (George, incoming of raw materials and improper handling. 2004). Intrinsic foreign body is associated with the According to Cordier (1994), chocolate should be food itself, example the shells of the cocoa beans. An tested for Staphylococcus aureus, coliforms, and extrinsic foreign body is introduced from external Salmonella. Aspergillus and Penicillium however are sources and includes matter such as glass, metal, responsible for mycotoxins. wood, plastic, insects and human hair. Sources of physical hazards during chocolate production and Pre-processing operations processing usually are from incoming raw materials, These include the quality determination of beans processing equipment and failures in pre-requisite before purchasing from the warehouse to be brought programmes (Burndred, 2009). to the factory for processing. At the warehouse samples of cocoa beans are taken by a horning Chemical hazards process. The cut test, bean count and the free fatty Two main sources of chemical hazards exist during acids test are performed on the dried fermented beans chocolate manufacture, the intrinsic contamination by the quality control department to assess the bean of raw materials and contamination that may occur quality. The results of these tests are analyzed and during the process. At high doses, the exposure to given serious consideration before cocoa beans are chemical contaminants can cause toxicity to the bought from the warehouse. Table 1 gives details of consumer, for example acute poisoning from the grade standards of cocoa beans. ingestion of high levels of lead (Burndred, 2009). At lower doses there are generally long-term adverse Cocoa processing into semi-finished products health consequences that will affect the consumer such Figure 2 shows the main flow scheme for the as kidney dysfunction, skeletal damage or productive processing of fermented cocoa beans into semi- deficiencies when cadmium builds up in the body finished products, namely: cocoa liquor, cocoa butter for many years (European Economic Commission, and cocoa powder. 2001). Raw materials of plant and animal origin are potentially affected by a number of contaminants Bean receipt and cleaning – CCP1 such as heavy metals, mycotoxins and pesticides. Raw cocoa beans are received from the warehouse 1774 Afoakwa et al./IFRJ 20(4):1771-1781 precursors arising from the correct fermentation and drying of the beans. The nibs become more friable and darken in colour after roasting. Roasting occurs in two stages, the first is a drying process in which the bean is subjected to low temperature heating. This dries and loosens the shell but has virtually no roasting effect on the nib as the temperature is unlikely to exceed 100°C. This initial heating is followed by higher temperature treatment, where the temperature may reach 125°C to130°C and this lasts for 7-11 minutes. Breaking and winnowing The roasted beans are broken down and the shells removed in a process called winnowing. The work of the winnower is to separate the shells as completely as possible from the nibs. This is checked by the quality assurance department by taking samples from each winnowing machine to determine the percentage of nibs in shells and shells in nibs, both should not exceed 1.5%. The separation by the winnowing process depends on the difference in the apparent density of the nibs in shell. The winnowing machines Figure 2. Flow chart for cocoa processing use a combine action of sieving and air elutriation. and discharged onto the platform. Beans are thoroughly Milling cleaned from all extraneous matter such as sticks, After roasting, the nibs are grounded into paste. stones, fibers, glass, human hair, metal fragments as The heat generated by the process causes the cocoa well as broken beans. The cleaning process starts with butter in the nibs to melt. Nibs contain about 48-57% the classifier. It is a physical cleaning method based cocoa butter (Fowler, 2009). The milling reduces on terminal velocity. The second stage of cleaning is particle size of the non-fat constituent and the paste termed the destoning stage. The destoner separates becomes progressively more fluid. The viscosity the stones from the cocoa beans. The destoners have of the liquor is related to the degree of roasting bores in the machine using counter current movement preceding the grinding and the moisture content of to separate the stones from the cocoa. the nib. The milling starts in SCS mills for coarse milling then Triple mills reduce the particle size Silos (storage) – CCP2 further before finally milling with the Attritor mills. The cocoa beans are then passed through a metal In the new system the Rheo mill is used first then detector before being stored in a silo. From the silo the NOVAS. Specified storage tanks are used to the beans move into the de-bacterization chamber. store cocoa masse between each milling operation. The milled particles should have 90% of particles De-bacterizer – CCP3 < 180 µm thus the fineness of the cocoa masse The de-bacterizer uses super-heated steam in a is tested in the laboratory by weighing 20 g of the stainless steel reactor, at 240°C and 4.8 bars for 3-5 masse, dissolving it in petroleum ether and sieving seconds to sterilize and minimize contamination at the dissolved masse in a sieve with a standard mesh the beginning of the production process. The steam size of 200 µm which allows only the fine particles treatment also loosens the shells from the nibs and to pass through. The percentage of the residue in the facilitates the breaking and winnowing steps in the cocoa masse is calculated to know the fineness of the production process. cocoa masse. The roasting process – CCP4 Storage and conditioning – CCP5 The roasting process has the objective to further The cocoa masse after milling is stored in large improve microbial quality and reduce water content tanks called Jumbo Tanks. Cocoa liquor from the to facilitate the ultimate grinding process. During Jumbo Tanks may be tempered and used in chocolate roasting there is the development of flavor from manufacture or sold as a semi-finished product. The Afoakwa et al./IFRJ 20(4):1771-1781 1775 liquor to be pressed is sent to the hydraulic presses and vanillin are obtained from other sources for the called Duyvis press that presses out cocoa butter chocolate factory’s processing operation. separating out the cocoa solids. Prior to pressing, a Liquor Conditioning System (LCS) is used to Mixing – CCP2 condition the cocoa liquid from the Jumbo Tanks at This is the initial stage of ingredients 95-98oC. homogenization. Mixing is done in a jacketed- pan called the kneader. Cocoa liquor, milk solids, Pressing – CCP6 sugar and cocoa butter are mixed in the kneader at The cocoa masse is pressed to obtain cocoa cake about 45oC. The mixing takes about 6 minutes. The and cocoa butter. The press takes 70 minutes to press quantities of various ingredients used are detailed 200 kg of cocoa masse at a pressure of 540 bars with in Table 2 below. The fat content is between 20- each pressing session to obtain cocoa cake and cocoa 25%. This allows coating of the surfaces of the solid butter. particles with liquid ingredients for refining and due to the high temperature, moisture content is decreased Centrifugation and filtration – CCP7 slightly. A viscous paste is obtained after mixing and The butter is filtered using a machine that functions a conveyor belt transfers the mixture to the refiner. like a centrifuge and filtered using special filter papers. The clarity and free fatty acid (FFA) content are Table 2. Quantities of ingredients used for milk chocolate tested by the quality assurance department. Clarity is per batch production tested using a polarimeter and its turbidity should not Ingredient Quantity exceed 100 NTU. The percentage of free fatty acids Cocoa Liquor 110 – 120 kg in the cocoa butter is calculated by titration using Milk Powder 140 – 180 kg cocoa butter, petroleum ether and sodium hydroxide. Sugar 180 – 350 kg Cocoa Butter 70 – 100 kg Kibbling and pulverization Lecithin 2 – 4 kg The cocoa cake obtained is kibbled and bagged Vanillin 300 – 400 g for sale or further pulverized into cocoa powder and bagged for sale as semi-finished products or stored Refining for later processing into finished cocoa products. This process breaks down further the tiny particles of milk, cocoa liquor and sugar within the mixture. Milk chocolate manufacture The process is done in two steps. First step is crude Figure 3 shows the main process flow scheme refining which takes place in a two-roll refiner. This for processing semi-finished products into milk breaks down the particles to about 100-200 µm. and chocolate. the mixture becomes semi-solid after this process. The second step involves the use of a five-roll refiner which reduces particle size to 18-35 µm (Afoakwa et al., 2007a). Powdered crumbs are obtained after this process. This is because the reduction in particle size increases the surface area for the liquid phase to be absorbed. Particle size less 15 µm gives chocolate a clogging effect and particle size greater than 35 µm renders the chocolate sandy (Afoakwa et al., 2007b). Conching The refined material is subjected to severe mechanical treatment of large heavy roller kneads which blends and grinds the mixture to produce a Figure 3. Flow chart for the processing of milk chocolate uniform smooth consistency. This process agitates the paste thus smoothing out the sugar grains to give Chocolate processing operations the chocolate a silky texture. The paste is also aerated Raw materials reception – CCP1 allowing acids and moisture to evaporate. This allows The raw materials for chocolate processing some of the natural volatile flavoring components such as cocoa liquor, cocoa solids and cocoa butter that do not have a favorable effect on the taste of are received from the previous cocoa processing the chocolate to escape (DeZann, 2006). Vanillin is operation. Others such as milk powder, sugar, lecithin added at this stage to enhance flavor and lecithin is 1776 Afoakwa et al./IFRJ 20(4):1771-1781 also added as an emulsifier. This process may last on the finished product. Hence, a vibrator is made to for 13-24 hours at temperatures 45-70oC. Conching shake each mould to level the liquid chocolate in the takes place in three stages. The initial stage is the dry moulds to release the air bubbles. paste stage which lasts from the start to the finish of the filling operation of the conching machine. The Cooling tough plastic phase is next and this offers the highest The moulds after vibrations pass through the resistance to the stirrers of the conche. The conche cooling section which is a multi-tier cooler. This operates at full power and moisture is evaporated off is a mechanised process that passes the moulds at a high rate. As demoisturizing and beating proceed gradually layer by layer through the cooler reducing the mass becomes softer. The last stage is known the temperature of the chocolate to about 12-15oC as wet conching and extra cocoa butter is added to solidifying the chocolate into bars. prevent the chocolate from spoilage and keep the De-moulding chocolate solid at room temperature. From the conch With optimized tempering and cooling, de- the mixture is stored in a storage tank before feeding moulding becomes a minor part of the process resulting into the temperer for temperature management. in good quality product. During demoulding, a small amount of force is needed to part the product from the Tempering mould and this is sometimes supplied by a hammer, Tempering is the process of cooling the melted aided by a mechanism that twists the moulds. Product chocolate to 50oC before it can be used to produce is de-moulded onto a belt which conveys chocolate other products. Tempering involves pre-crystallization onto plastic trays. These trays are collected onto of a small proportion of triglycerides, with crystals trolleys and wheeled to nearby wrapping plants. The forming nuclei (1-3% total) for the remaining lipid to period between the deposition on trays and wrapping set in the correct form. Tempering has four key steps: is known as the drying stage where excess moisture melting to completion (at 50oC), cooling to point of on the surface of the products is lost. crystallization (at 32oC), crystallization (at 27oC), and conversion of any unstable crystals (at 29-31oC) Wrapping/packaging – CCP4 (Talbot, 1999). Time-temperature combinations are At the wrapping plants, trays of chocolate are of paramount importance in the process design and emptied onto a conveyor belt which transports in continuous tempering, molten chocolate is usually chocolate into the wrapping machine. The wrapping held at 45oC then gently cooled to initiate crystal machine, depending on the grams/size of the chocolate growth (Afoakwa et al., 2008a,b). During tempering, cuts aluminium foil and picks up a paper wrapper. The the temperatures are precisely controlled and agitation aluminium foil initially covers the chocolate before provided enhances nucleation rates. As the viscosity the paper wrapper. The foil provides the best barrier increases, the chocolate is reheated again in the third to water vapour, gas transmission, maintaining aroma stage to prevent runway solidification (Afoakwa, and cool temperature of the chocolate. The paper 2010). In the fourth stage, crystals are matured. This material is also chosen because it is strong, easily results in the final good surface gloss and colour, printed and relatively inexpensive. The machine then good snap, smooth and fast melting and good heat labels the chocolate with the batch number as well as stability. the production and expiry date. Wrapped chocolates without any defects are manually picked and boxed Casting and moulding – CCP3 before sending to the warehouse for storage at The temperer sends the tempered mixture to the temperatures between 18-20ºC. Chocomaster, an automated system for moulding and demoulding of chocolate. The mixture first enters Hazard analysis the hopper of the depositor which deposits chocolate The hazard analysis worksheets in Tables 3 and into 20 g, 50 g and 100 g moulds depending on the 4 show the different process steps which were each selected mould type. The depositor automatically fills associated with different risk assessment values. molten chocolate into moulds which are set to be of These range widely from 1-16 with one being the least the same temperature as the chocolate. If the moulds value. These values were obtained by multiplying the are too hot, detempering would occur resulting in occurrences and severity values and they serve to the product sticking in the impressions of the mould choose among the hazards listed for a food product, leading to poor gloss and bloom. If they are too cold, especially those that are likely to or severe enough poor gloss and sticking in the mould can result with to warrant preventive action (Arvanitoyannis and an increase in the number of air bubbles and markings Varzakas, 2008). Afoakwa et al./IFRJ 20(4):1771-1781 1777 Table 3. Hazard analysis worksheet for semi-finished products Product: Semi-Finished Cocoa Products Process: Bean reception, Cleaning, Metal Detection, Silo (storage), De-bacterization, Roasting, Winnowing, Milling, Conditioning, Pressing, Centrifuging and Filtering, Tempering, Kibbling and Pulverisation Process step Hazard Category Hazard Assessment Control/Preventive Measure Monitoring Procedure Officer O S RA Responsible No. 1 Bean reception Contamination with glass, fibres, Physical 4 4 16 Use of vibrating screens, classifier, destoner and an Equipment cleaning Factory / wood plastic, human hair, ferrous effective metal detection device. ............ every two hours during ProductionM and non-ferrous metals bean cleaning anager. Quality Check effectiveness of Assurance metal detector using Manager 0.1mm Fe test piece Insect infestation Physical 1 4 4 1. Insistence on buying readily fumigated Cut-test on every batch Quality beans of cocoa beans received Assurance 2. Regular supply audits Every three months Manager Contamination with pesticide Chemical 4 4 16 Supply audits to ensure use of approved Before purchasing cocoa Quality residue, heavy metals and fumigants/insecticides and to ensure that adequate beans Assurance mycotoxins waiting period after application of chemicals was Manager observed. Contamination with moulds. Microbiological 1 4 4 Regular check for mouldy beans Cut-test Quality Assurance Manager 2 Silos (storage) Mould growth Microbiological 2 4 8 1. Effective air circulation and temperature With every batch of Factory / management systems cocoa beans stored Production 2. Avoid long storage of cocoa beans. Manager Every two hours 3 De-bacterization Contamination with Staphylococcus Microbiological 1 4 4 1. Check steam boiler and pipes for adequate With every batch Factory / aureus, coliforms, Salmonella, heat supply With every batch Production Aspergillus and Penicillium 2. Ensure that pressure system and delivery Manager valves are functioning adequately 4 Roasting Contamination with Staphylococcus Microbiological 1 4 4 Monitor roasting temperature of roasters. Every thirty minutes Factory / aureus, coliforms, Salmonella Production Manager 5 Breaking and Contamination of nibs with shells Physical 4 1 4 Collect samples from winnowers to determine the Every thirty minutes Quality Winnowing shell in nibs as well as the nibs in shell ratio Assurance Manager 6 Milling Physical contamination of mass eg Physical 1 4 4 Good maintenance practices Every maintenance Factory / metal shavings or residues session Production Manager 7 Conditioning Microbial contamination Microbiological 2 4 8 Regular checks of temperature of mass in the tanks Every forty five minutes Factory / Production Manager Contamination with metal residues Physical 1 4 4 Good maintenance practices Every maintenance Factory / session Production Manager 8 Pressing Hydraulic oils may spill into cocoa Chemical 4 3 12 Use of food grade oils for the press machine Every batch constantly Factory / mass when pressing Production Manager 9 Centrifuging and Physical contamination with cocoa Physical 4 1 4 Check clarity with a polarimeter Every thirty minutes Quality Filteration solids Good maintenance practices With every batch Assurance Manager Factory / Production Manager 10 Tempering Microbial contamination Microbiological 2 4 8 Good maintenance practices and good hygienic Every batch constantly Factory / practices Production Manager 11 Kibbling and Contamination of mixture with metal Physical 1 4 4 Good maintenance practices Every maintenance Factory / Pulverisation shavings session Production Manager Table 4. Hazard analysis work sheet for milk chocolate production Product: Milk Chocolate Process: Raw materials reception, Mixing, Refining, Conching, Casting and Moulding, Wrapping and Labelling, Secondary Packaging, Storage. No. Process step Hazard Category Hazard Control/Preventive Measure Monitoring Procedure Officer Assessment Responsible O S RA 1 Raw materials Contaminated raw materials Microbiological 4 4 16 Microbiological count of Every batch of raw materials Quality reception introduce salmonella and microorganisms present and perform received Assurance other microorganisms regular supply audits Manager 2 Mixing Contamination with plastic, Physical 3 4 12 Ensure good manufacturing practices Every time mixer is being Factory / fibre, hair or metal filled Production Manager 3 Refining Contamination of mixture Physical 1 4 4 Good maintenance and sanitation Every week Factory / with metal shavings or practices Production residues Manager 4 Conching Contamination of mixture Physical 1 4 4 Good maintenance and sanitation Every maintenance session Factory / with metal shavings or practices Production residues Manager 5 Casting and Microbial contamination Microbiological 2 4 8 1. Heat treatment of moulds Just before casting Factory / Moulding 2. Good hygienic and Constantly Production maintenance practices Manager 6 Wrapping and Microbial contamination Microbiological 2 4 8 Good hygienic practices and proper With every batch constantly Factory / Labelling handling of wrapping materials. Every batch produced Production Manager Check microbial counts 7 Storage Odours, Sugar bloom and fat Physical 1 4 4 Effective air circulation and Monitored every two hours Factory / bloom temperature management systems Production Manager Key No. – Number, O – Occurrence, S – Severity, RA – Risk Assessment 1 = Lowest Rank – 4 = Highest Rank in the occurrence and severity columns The figure presented in the risk assessment columns is the product of the occurrence and severity values. 1778 Afoakwa et al./IFRJ 20(4):1771-1781 Table 5. Identification of Critical Control Points (CCPs) based on HACCP decision tree (Codex Alimentarius, 1999) for semi-finished products Processing Step Hazard Do preventive Is the step Could Will a Is the control specifically contamination subsequent step processing step measures designed to with identified eliminate identified a CCP? exist? eliminate or hazard(s) occur hazards or reduce reduce the likely in excess of likely occurrence occurrence of a acceptable level(s) to an acceptable hazard to an or could these levels? acceptable level? increase to unacceptable levels? Physical Yes Yes - - CCP1 Bean Chemical Yes No Yes No CCP1 Reception Microbiological Yes No Yes No CCP1 Silos (storage) Microbiological Yes Yes - - CCP2 De-bacterizer Microbiological Yes Yes - - CCP3 Roasting Microbiological Yes Yes - - CCP4 Breakingand Winnowing Physical Yes No No - Not CCP Milling Physical Yes No No - Not CCP Microbiological Yes Yes - - CCP5 Conditioning Physical Yes No No - Not CCP Pressing Chemical Yes Yes - - CCP6 Centrifuging Physical Yes Yes - - CCP7 and Filtration Tempering Physical Yes No No - Not CCP Kibbling and Pulverisation Physical Yes No No - Not CCP Table 6. Identification of Critical Control Points (CCP) based on HACCP decision tree (Codex Alimentarius, 1999) for milk chocolate production Processing Step Hazard Do preventive Is the step Could Will a Is the control specifically contamination subsequent step processing measures designed to with identified eliminate step a CCP? exist? eliminate or hazard(s) occur identified reduce the likely in excess of hazards or occurrence of a acceptable level (s) reduce hazard to an or could these likely occurrence acceptable level? increase to to an acceptable unacceptable levels? levels? Raw materials reception Microbiological Yes Yes - - CCP1 Mixing Physical Yes Yes - - CCP2 Refining Physical Yes No No - Not CCP Conching Physical Yes No No - Not CCP Casting and moulding Microbiological Yes Yes - - CCP3 Wrapping and labelling Microbiological Yes Yes - - CCP4 Storage Physical Yes Yes No - Not CCP A hazard such as the contamination of cocoa hazards due to the high physical contamination liquor with metal shavings or residue as well as of raw materials, physical contamination during other physical hazards such as loose screws, paper processing and physical hazards due to failures of or plastics is low and the milling process step pre-requisite programmes (Burndred, 2009). The has an associated risk assessment of 4 because highest risk assessment for physical contamination the likelihood of occurrence is low due to good was observed with the receipt of dried fermented maintenance practices. The risk assessment for cocoa beans which was 16 due to high risk of severity microbial contamination associated with spoilage and occurrence. The most predominant hazards for and pathogenic microorganisms with raw materials milk chocolate manufacture were microbiological receipt for chocolate production was 16 because the and physical hazards. The use of regular supply audits various raw materials carry these microorganisms, on raw materials reception, Good Hygienic Practices for example, milk powder has been implicated in a (GHPs), Sanitation Standard Operating Procedures large number of salmonellosis outbreaks (Bell and (SSOPs) and good maintenance practices eliminate Kyriakides, 2009). these microbial and physical hazards. The major hazards identified in the processing of cocoa beans and chocolate manufacture were physical, Determination of critical control points microbiological and chemical in nature. The most Tables 5 and 6 show the determination of predominant hazards for cocoa processing are physical critical control points (CCPs) for production of Afoakwa et al./IFRJ 20(4):1771-1781 1779 Table 7. ISO 22000 analysis worksheet for the determination of pre-requisite programmes for semi-finished cocoa products Processing step Are the technical Is it Do they Does the Is it a infrastructure and feasible contribute in the effectiveness of pre-requisite the preventative to control of the remaining programme? maintenance evaluate recognisable food control measures programme adequate? them? safety hazards? depend on them? Bean reception Yes Yes Yes No No Silos (storage) Yes Yes No No Yes De-bacterization Yes Yes Yes Yes Yes Roasting Yes Yes Yes Yes No Breaking and Winnowing Yes Yes No Yes Yes Milling Yes Yes No No Yes Conditioning Yes Yes No Yes Yes Pressing Yes Yes No Yes Yes Centrifuging and Filtration Yes Yes No No Yes Tempering Yes Yes No Yes Yes Kibbling and Pulverisation Yes Yes No No Yes Table 8. ISO 22000 analysis worksheet for the determination of pre-requisite programmes for milk chocolate Processing step Are the technical Is it Do they Does the Is it a infrastructure and feasible contribute in the effectiveness of pre-requisite the preventative to control of the remaining programme? maintenance programme adequate? evaluate recognisable food control measures depend on them? safety hazards? them? Raw materials reception Yes Yes No Yes No Mixing Yes Yes No Yes Yes Refining Yes Yes No Yes Yes Conching Yes Yes No Yes Yes Casting and moulding Yes Yes No Yes Yes Wrapping and labelling Yes Yes No Yes Yes Storage Yes Yes No No Yes Table 9. Comparative presentation of CCPs determined the determination of the pre-requisite programmes for with HACCP and ISO 22000 analyses in conjunction with the processing of cocoa into semi-finished products pre-requisite programmes for cocoa processing and for the manufacture of milk chocolate. Tables 7 Processing step CCP according to Pre-requisite programmes CCPs according HACCP (ISO 22000) to ISO 22000 and 8 show the identified pre-requisite programmes Bean reception Yes CCP1 No CCP1 for semi-finished cocoa products and milk chocolate Silos (storage) Yes CCP2 Yes No De-bacterization Yes CCP3 Yes No respectively. Nine pre-requisite programmes were Roasting Yes CCP4 No CCP2 identified for production of semi-finished cocoa Breakingand Winnowing No CCP Yes No Milling No CCP Yes No products while six pre-requisite programmes were Conditioning Yes CCP5 Yes No Pressing Yes CCP6 Yes No identified for milk chocolate manufacture. Centrifuging and Filtration Yes CCP7 Yes No The questions frequently asked for each Tempering No CCP Yes No Kibbling and Pulverisation No CCP Yes No processing step involve those regarding the adequacy of the technical infrastructure and preventive Table 10. Comparative presentation of CCPs determined maintenance, the feasibility for their evaluation, their with HACCP and ISO 22000 analyses in conjunction with pre-requisite programmes for chocolate production contribution in the control of recognisable food safety hazards, whether the effectiveness of the remaining Processing step CCP according to Pre-requisite programmes CCPs according HACCP (ISO 22000) to ISO 22000 control measures depends on them (Mensah, 2010). Rawmaterials reception Yes CCP1 No CCP1 The answers to these questions determine whether Mixing Yes CCP2 Yes No Refining No CCP Yes No a process step is a pre-requisite programme step or Conching No CCP Yes No Castingand moulding Yes CCP3 Yes No not. Tables 9 and 10 present the comparison between Wrapping and labelling Yes CCP4 Yes No the application of HACCP and ISO 22000 analysis Storage Yes CCP5 Yes No worksheets to the processing of cocoa into semi- semi-finished cocoa products and milk chocolate finished products and milk chocolate manufacture manufacture respectively, based on the HACCP respectively. decision tree (Codex Alimentarius Commission, 1999). Seven critical control points were identified Conclusion for the production of semi-finished cocoa products while four critical points were identified for the During cocoa processing and chocolate manufacture of milk chocolate. manufacture, physical hazards such as metals, stones, fibres, plastics and papers; chemical hazards such as Determination of pre-requisite programmes pesticide residues, mycotoxins and heavy metals; The ISO 22000 analysis worksheet was used in and microbiological hazards such as Staphyloccous 1780 Afoakwa et al./IFRJ 20(4):1771-1781 aureus, coliforms, Salmonella, Aspergillus and International Journal of Food Science and Technology Penicillium were identified. Good Manufacturing 43: 1729-1741. Practices (GMPs), Good Hygienic Practices Arvanitoyannis, I. S. and Varzakas, T. H. 2009. Application (GHPs), Sanitation Standard Operating Procedures of ISO 22000 and Comparison with HACCP on (SSOPs) and maintenance systems with written and Industrial Processing of Common Octopus (Octopus well documented pre-requisite programmes were vulgaris). International Journal of Food Science and Technology 44: 58-78. implemented to ensure the safety and quality of the Bell, C. and Kyriakides, A. 2000. Salmonella - A Practical processing of cocoa beans into liquor and cocoa Approach to the Organisim and its Control in Food, powder, and in chocolate manufacture. The HACCP Blackwell Science, London. pp. 160-163. decision tree was employed to determine CCPs, and Blank, D. 2006. From Intent to Implementation. ISO seven CCPs including bean reception, storage in silos, Management Systems 5: 1-5. de-bacterization, roasting, conditioning, pressing, and Burndred, F. 2009. Food Safety IN Chocolate Manufacture centrifugation and filtration were identified for the and Processing. In S. T. Beckett, Industrial Chocolate th cocoa processing operations. Four CCPs including Manufacture and Use 4 ed. Wiley-Blackwell raw materials reception, mixing, casting and Publishing, UK. pp. 530-550. moulding, wrapping and labelling, were identified Case, C. L. 2010. The Microbiology of Chocolate. Retrieved from http://www.smccd.edu/accounts/case/ for the chocolate manufacturing operations. chocolate.html on February 12, 2011. In the application of the ISO 22000 requirements, Codex Alimentarius Commission. 1999. Food Hygiene. In the seven CCPs identified for the cocoa processing Basic Texts 2nd ed. Codex Alimentarius Commission, operation using the HACCP system were reduced to Rome, Italy. pp. 33-42. two, namely bean reception and the roasting process European Economic Commission 2001. Setting Maximum steps; and only one CCP - the reception of raw Levels for Certain Contaminants in Food Stuffs. materials was obtained for chocolate manufacture. The Official Report of the European Communities. (EC) reduction in CCPs was due to the elimination of pre- No. 466/2001 requisite programmes from the cocoa processing and Cordier, J. L. 1994. HACCP in the Chocolate Industry chocolate manufacturing steps. Thus, the application Food Control. Food Control 5: 171-175.DeZaan. 2006. The De Zaan Cocoa Manual. ADM Cocoa of ISO 22000 worksheet with HACCP in identifying BV, Netherlands. CCPs makes the implementation of the HACCP Faergemand, J. and Jespersen, D. 2004. “ISO 22000 to system simple, more effective and manageable since Ensure Integrity of Food Supply Chain”. Retrieved less CCPs were obtained. from http://www.iso.org/iso/tool5-04.pdf. Accessed February 28, 2008. References FDA 1994. Food Safety Assurance Programme: Development of Hazard Analysis Critical Control Afoakwa, E.O., Paterson, A. and Fowler, M. 2007a. Points: Proposal Rule. Fedural Register. August 4, Factors influencing rheological and textural qualities 1994. in chocolate - a review. Trends in Food Science and Fowler, M. S. 2006. Cocoa Beans: From Tree to Factory. Technology 18: 290-298. In S. T. Beckett, Traditional Chocolate Manufacture Afoakwa, E. O., Paterson, A. and Fowler, M. 2007b. and Use 4th ed. Wiley-Blackwell Publishing, UK. Pp. Effects of particle size distribution and composition 10-47. on rheological properties of dark chocolate. European George, R. M. 2004. Guideline No.5 Foreign Bodies in Food Research and Technology 226: 1259-1268. Foods. Guidelines for their Prevention, Control and Afoakwa, E. O., Paterson, A., Fowler, M. and Vieira, J. Detection 2nd ed. Campden and Chorleywood Food 2008a. Particle size distribution and compositional Research Association Group. effects on textural properties and appearance of dark ISO 2010. The ISO Story. Retrived from http://www.iso. chocolates. Journal of Food Engineering 87: 181 – org/iso/about/the_iso_story.htm. Accessed November 190. 26, 2010. Afoakwa, E. O., Paterson, A., Fowler, M. and Vieira, J. Llano, L. 2011. Advantages of HACCP. Nirvanita de Baja. 2008b. Modelling tempering behaviour of dark Retrieved from http;//agricorganicos.com/special/ chocolates from varying particle size distribution Advantage.html. Accessed February 12, 2011. and fat content using response surface methodology. Mensah, E. M. 2010. Application of ISO 22000 and Innovative Food Science and Emerging Technologies Comparison with HACCP to the Processing of 9: 527-533. Vacuum-packed Pouched Tuna Chunks in a Fish Afoakwa, E. O. 2010. Chocolate Science and Technology. Processing Company in Ghana. Thesis submitted to Wiley-Blackwell Publishing, Oxford, UK. pp. the University of Ghana, Legon. 1-5. Arvanitoyannis, I. S. and Varzakas, T. H. 2008. National Sanitation Foundation 2004. ISO 22000 Benefits. Application of ISO 22000 and Comparison to National Sanitation Foundation International. February HACCP for Processing of Ready to Eat Vegetables. 12, 2011. Afoakwa et al./IFRJ 20(4):1771-1781 1781 Prati, R. and A, M. D. 2004. The new ISO 22000 norm on food safety management. Ingredienti Alimentari (Chiriotti Fditori) 3: 19-21. Silliker, J. H. 1995. Mocrobiological Testing and HACCP Programmes Scope. Siller Laboratories Homewood, IL, USA. Report 10 (2). pp. 13-18. Talbot, G. 1999. Chocolate Temper. In S. T. Beckett, Industrial Chocolate Manufacture and Use 3rd ed. Blackwell Science, Oxford. pp. 218-230. Van Schothorst, M. 2004. A Simple Guide to Understanding and Applying the Hazards Analysis Critical Control Point Concept 3rded. International Life Standards, Europe. Whitehead, A. J. and Orriss, G. 1995. Food Safey Through HACCP - The FAO approach. retrieved from http:// www.fao.org/docrep/v9723t/v9723t0e.htm. Accessed February 12, 2011. View publication stats