@5-

Eoo oroducts oroductlon flow dlaqram

@==i-
Eoo nroducfs oroductlon flow diaqram
@E!!!-
Eoo whila oroduction flow dlaqram
Ih*t b."b"""ll
E""'"sl
I
pacmng
I
l-'r
i
:
;
*!,g *
@HP-
Gocoa & Nut Processing
Part
I
..
n;|'.
';i
' 1'.'
ffi) s!!:.-
OUTLINE
r Purposeand objective
r From farms to the processing plants: harvesting and
cleaning
r Roasting
r Using Cocoa Expectation & Nut Expectations
a|^o^'//a
ffi) E!+-
PURPOSE
r To highlight major food safety points in cocoa and nut
processing
OBJEGTIVE
At the end of this training session you will;
r Understand the basics ofcocoa and nut processes
r Be able to identify and describe the operations of
different heat treatments
@/
s!.s:-
History: Peanut Butter recall - Kraft Foods Australia 1996
r Health officials reported 550 illnesses from
Salmonella-
r The Sarmonel/asource was idenlified at the supplier
as unclean equipment and inadequate storage d
processed nuts (evidence of bird droppings)
r The Peanut butter was widely distributed and used as
an ingredient in other Producls.
r The total cost oflhe recall tothe businesswas in the
region of $20 Million'
tffi>
==E:- :
From Farm to Factory: cocoa
ffi@
Grmeotation
ffi
transportaliofl
(@i) E=!=--
From Farm to Factorv: nut
manual seleclion
W
harvest
@
hansportalion receiving
2
r-
<ffi-r !=E
-
:
From Farm lo Factorv
risks reloted to
I
I
l
Chemical
this nuts????
\
Ph!'sical
stones. arth,
dust
How to pnevent these risks???
2l
,l
I
I
I
I
-J
i
i
L
L,rtfy
b//'t"
-T
Hlstory isgtmoierra-tst nrGlpeairits' .
'i.
*'r,,!.,
r Ngts/peahuts are harvested from the natural
-
'"
'*rvtrin*lent and con#qU6ntly'tfreshells abi" r.*! . r \
-
contaminated with low levels ot Sahnonella and other
bacteria from bird feces
and soil.
;
.,;
i
, , J'
r De-shelling removes the majority of the microbial
contamination, but subsequenl storage and
transportation of the de-shelled nulypeanuts creates
opportunities fot Salrnonella contamination from soil,
dust, insects, birds and rodents- especially when GMP's
are inadequate.
@
E=r--
History : Salmonella in nuts/peanuts
.
Previously, nuUpeanut processing was not a Food
Safery step, but a Quality step (to change colour,
flavour or remove skin)
.
Nuts/peanuts and nut derived products are used in
confectionery with no further processing. Any
potential Salmonella present are able to survive within
the chocolate.
.
Raw materials and finished product tesling for
Salmonella is not sufficient to detect spot
contaminatlon.
3
sorting by size
soring by danstty
1. '
l
@r.b
..DtfferentcGP'.lli.9dels'F,
a Different types of processes in use for manufacturing
of nuupoanuts and their products.
'-
:
r Therefore there are dlfferent GCP Models.
r Hazardr Biological (Vegetatiye)
r Targee Reduce 2 Jogs Salmonella
r Process Steps:
- Dry Roasting
- Drum Roasting
- Ol Roasting
- Blanching
<ffi-r
=!.!=-
Roastlno: orlncloles
r Heatlng medium: water, oil, air, steam?
r Batch or continuous process?
I Whlch CGP model should be used?
I How is tho temperature measured? Records?
I Corrective actions in case of heat treatment failure?
4
I
J
I
I
i
j
i
i
I
i
j
Xraft Foods
ffi-
NuUpeanut Roasting
tffir rg=!--
:
CCP Models: Drv Heat Treatment
Belt Roaster (e,9. Proctor)
@!*u=--
Audit Focus: Nuupeanut roasting
.
ls lhe @sting tempeEtuE m$red belwem lhe nu!s? It it is not
pNble, ms $le pffi wlidated?
.
Whal is he Hkttrce time of lhe ruts h the rsling zme? (mlhg
zone exduded)
.
Are the applied time.^empeEtJre paBreters $fficient to mst the KF
rcP modd "Dry masling of nuts?
.
ls the lempeEture cotded @tinuoiJslt/.?
.
Are he hemometetvrecorde6 libEted at leasl once per six mmtl?
.
ls the flM mnfd syslem calibEied at least mce per six mmth and
after mintenance activitis?
.
ls fle flow te do@milted at least once por shn and atter belt speed
changes?
(]@@D>
r4!:!-
GCP Model: NuUPeanut drum batch
Drum Roaster (e,9. Probat)
WW
I
t
j
,,
K cZ
,r/.
fr#t r<
+^rAi'.o-
-Jan
in
,J
a@rr,) E4=__
Audit Focus: Drum batch
.
ls the Daslku lmprat@ meN@d
btues tie nub / @H6l localbn? f it b nol
Fsble, wa3 lhe D@ litated?
. AFlhe appli, tindtmpet rc p6@eteE
suffEieil b meet the KF CCP trDdd?
. ls tho lmpeEture @dh@dy mitored?
. Are ihe theffie{ersr.@deF cslibded d
led one ps sir mnth? It the @lhg ak
fitered or b the ek micrcbial eluated?
q-\
I
I
i
!
l
t
j
<ffi-r !==f,--
:
GCP Modelt NuUPeanut oil Roastlrig
Cooler (e.9. Florigo)
Oil Roaster
(e.9. Florigo)
@
!!E!-
Oil roastlng flow diagram,
ti.nut FKting fltnt
ra */:
s{t
,i 4"
L/r/
"*&-Zd
^tlt7rca4clr-
p &:-
tt' <-
.;/)'1 fi 1e
".,,
4r;
q*
/ il/*/
.;/ ,F'r6
3
-
yr+t cr
.
ks,,f
,
{- t"
o, c a*tzo--
C, ,
I tL.,t
rffir EE!-
:
Audit Focus: Oil roastino
ws the retentm Bne h tB tr)r ffised?
Ae KFI CCP t&neftsnpqatuc slukffdls met?
ls @nthws tdnperatu@ @rding pettomd?
ls calbEtlor ot lrr4rhg devic6 p.iomed?
ls the Fan6portatir 69eed tsded o@ pq
$tt?
w6 he rbk of dl4ff .ry ow sesg? (e 0
R@t {
padiclB (@ding} in the ol fM pGvbs
proddbns)
AG th@ any GlrO iss regatdiog rne tqlhg ol?
ls the @lhg air filtded or is the ai
mircbid Mllated?
lhbl +
lPduc
t
@srr+-
CCP Model: Nut Blanching
Almond Blanchlng
!i
l
*
ll
tt
lti
lt
tt
li
tt
lt
IJ
i
j
i
i
i
I
ii
lr
i!
t,
@ =$=-
Almonds Blanchlng & Marzlpan
production flow diagram
.
HH
bbdry*
Ft Y,
X /4')
\ffi
Bhf'htd
@Hb
Audit Focus: Almonds Blanchins
&bn d bhrcilE
drpHg
' .
ls the addlliw fo. addl'ifon food
gra(b?
.
Do 0)e paEmeteB meel lhe
.
quiFmsts of 0|e KF CCP moden
.
ls lha blandirE tempEtuc msured
at lhe @ldest lotim?
.
18 calibEtlon of lempeBtuc
pEbes/corder
Perfomed?
.
Hwdowahrrylheesidencetime?
.
ls the blancfiing lempeEtuP
@ntinu0sly rcnitored?
'
ls zoning approptiaie? (subsequnt
steps shall be in the nalEl zme)
Bhmnl6 ot
sglhh
4
j
J
l
I
i
I
J
I
I
_J
i
I
I
!
j
<ffir
=E=--
Audit focus: Maaioan cookino
(after
blanchingl
@
E!4-
Audit Focus: Marzloan
&dilbrd
lry.dbdr
.
Do the paEmbF rleal lhs
requlremnls o[ thq KF CCP model?
. ls lhe lempeEtjn rosuted at lhe
coldest loetitr?
.
ls the tempet E Ecorded?
- ls libEuon of bmpcEtJre
pbbev@rder pertomed?
- lf jackal @ling is applied is lhe te
d@lated ter testd? (mlmbial
tsting)
.
ls diEct stm inisllrr applied? It y6,
ls it @linary stm as pr KFI
detinitim?
kFtr dtE .
weB irpred'sts as6sed on
allergeos?
.
Was snEphilic )@sl
spoibge tisk
mnslderedmtroiled by suppller?
I
@ =.!!-
Marzioan cookino: Control of osmoohilic veasf
Osmophilic )ast haw to be @ntmlled by ht trlnent I G20
minutes al 93'C1oO'C unles me of ths folleing is trsued:
-
Finished
Foduct Mter activity is <0.60 (evis tomula ptior iho
audit)
-
Addtm of 1 -2% alcohol by reight on applition
The audibr shall dEck micrcbial requirements of fle Ew mtedal
specifilion. As a requirement shall be statd: absene of Gmphilic
yeast in 5Og, smpling: 509, n=10, r-0
TI
l
t
U
u
tl
tt
L]
t.
t.
@
!t!!:-
Rf.n: Th.niaf lffi qlpq
A Crillc.l Con$ol Pot&
of theflnal kill steps?
points todted<?
-
lhrtl'Tdemnnh rrril lodd@rt
-
Ala I rs
qprlymtil |trcEfil
ErSrclnfib.lal? lEiffi-l
lffiiiFt
lEi....ltc 1
tffil
Hilb *n .6?Conhdbi gr h onE
rflrtod$?
Le&odrEaa(*chlt !6dldb!d,
l- orrfrilnl3h b.d
vl3.lbn o,O. 169-ttr6ts-a Don
3c d rha il nr-t vdaL $ar,r-?
ffthin iElttJt
EGi Ia-rcilld d h i- lroCr lEl d!9
rod.d? l,tut b didtt
TaF.-nlbrrfie rCi.crht
&ndbioJarEdaiEld r|ilbrt
(hd. bd tt-dt.tn firincb.
UdShrdmrcadc
Flt&r dGlErl? Fqrfftot
,tdg''tfl
@dlrJbgucF-r0
la
6