A model for implementation of HACCP system for prevention and control of mycotoxins during the production of red dried chili pepper

OZTURKOGLU-BUDAK, Sebnem

doi:10.1590/1678-457X.30316

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Food Science and Technology

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Research Paper • Food Sci. Technol (Campinas) 37 (suppl 1) • Dec 2017 • https://doi.org/10.1590/1678-457X.30316 copy

A model for implementation of HACCP system for prevention and control of mycotoxins during the production of red dried chili pepper

Authorship SCIMAGO INSTITUTIONS RANKINGS

Abstract

Hazard analysis and critical control points (HACCP) is a process control system describes the potential hazards during food production flow chart. In contrast to the conventional way of ensuring product safety by end-product testing, HACCP establishes control systems, focuses mainly on preventive measures. Quality of red dried chili pepper (RDCP) should be assured by taking special care from harvesting of the peppers to retailing of the packaged product. RDCP is susceptible to fungi growth and mycotoxin contamination depending on the atmospheric and processing conditions such as humidity, temperature, storage and drying. Mycotoxins, are toxic metabolites to human health and strict control measures are required for preventing their occurrence in RDCP. In this study, HACCP system was implemented during the production of RDCP to ensure the food safety and quality characteristics of products and to expand the market. The most important critical control points (CCPs) during the production of RDCP was determined as sorting and drying. It is evident that development and use of the GMP, GAP, GSP and hygienic rules as well as HACCP during handling and processing of dry chili pepper are a must for processing plants.

Keywords:
dry chili pepper; HACCP; aflatoxin

Principles
1. Conduct hazard analysis 2. Determine the critical control points (CCPs) 3. Establish critical limits 4. Establish a system to monitor control of each CCP 5. Establish the corrective action to be taken when CCP is not under control (a deviation from a critical limit) 6. Establish procedures for verification to confirm that the HACCP system is working effectively. 7. Establish documentation concerning all procedures and records appropriate to these principles and their application.
Tasks
1. Assemble HACCP team 2. Describe product 3. Identify intended use 4. Construct flow diagram 5. On-site confirmation of flow diagram 6. List all potential hazards associated with each step, conduct a hazard analysis, and consider any measures to control identified hazards 7. Determine Critical control points 8. Establish critical limits for each CCP 9. Establish a monitoring system for each CCP 10. Establish corrective actions 11. Establish verification procedures 12. Establish documentation and record keeping

Process stage	Potential Hazards	Preventive Measures	CCP/not
Pre-harvest, Harvest	B: Fungus, Bacteria, Insects, Rodents	B: In designing the lay-out of orchard, information concerning plant spacing will be obtained. Orchard surface should be prepared before planting for prevention the growth of mycotoxin producing fungi	CP
	P: Soil, materials, glass, wood, stone	P: GAP
	C: High/low usage of Pesticide, Aflatoxin contamination	C: GMP, Good Hygienic Practises (GHP)
Washing and Sorting	B: Fungus, Bacteria, Insects, Rodents, Dirty water/Contamination	B: Washing should be done with clean water, Personnel hygiene, GMP	CCP1
	P: Soil, materials, glass, wood, stone	P: Direct contact to soil must be prevented
	C: Aflatoxin contamination	C: Peppers after harvesting will be sorted to remove demaged peppers and foreign materials. They should be transported as soon as possible for immediate processing in clean, dry, protected against humidity and free of insects and fungal growth containers
Drying	B: Fungus, Bacteria, Insects, Rodents, contamination from personnel	B: Personnel hygiene, GMP	CCP2
	P: Soil, material	P: Direct contact to soil should be prevented.
	C: Contamination of aflatoxin	C: Drying of pepper must begin as soon as possible.Then, insects, mites, wormin, domestic animals, fungi, chemicals, microbial contaminats and dust should be prevented by GMP. Fluidized bed can be used as quick drying.
Aflatoxin Analysis	B: Generally not	B:-	CCP3
	P: Generally not	P:-
	C: Aflatoxin amount determination	C: Aflatoxin level should be detected, if the total aflatoxin amount is higher than 10 ppb, quarantine the batch and apply correction practises. e.g. irradiation
Storage in bulk	B: Fungus, Bacteria, Insects, Rodents	B: Containers and warehouse have to be clean, dry and free of visible fungal growth, insects and any contaminated material. The containers should be well constructed to withstand handling abuse without breaking or puncturing, and tightly sealed to prevent any access of dust, fungal spores, insects or other foreign material. Good Storage Practises (GSP) will be applied.	CCP4
	P: Generally not	P: -
	C: Aflatoxin contamination	C: Relative humidity and temperature of warehouse have to be setas; RH <70%, T < 5°C for the inhibition of fungus growth and aflatoxin occurence.Water activity of product should be checked; Aw < 0.7. Controlled atmosphere storage (CAS), Modified atmosphere storage (MAS) might be applied
Packaging	B: Fungus, Bacteria, Insects, Rodents	B: Areas where raw materials are going to be received or stored will be physically separated from areas in which final product preparation or packaging is conducted as to preclude contamination of the finished product. GMP will be applied. Yeast and mold number in the end-product should be max 1x10² cfu.mg^-1	CCP5
	P: Contamination from packaging material	P: Analysis of packaging material
	C: Aflatoxin contamination	C: Aflatoxin analysis
Storage (Packed RDCP)	B: Fungus, Bacteria, Insects, Rodents	B: Good Storage Practices (GSP)
	P: Generally not	P: -
	C: Aflatoxin contamination	C: GSP
Transport	B: Fungus, Bacteria, Insects, Rodents	B: Containers must be clean, dry, and free of visible fungal growth, insects and any contaminated material.	CP
	P: Generally not	P:-
	C: Aflatoxin contamination	C: GMP

CCP	Potential hazards	Critical Limits	Monitoring				Corrective measures	Records	Verification of CCP
CCP	Potential hazards	Critical Limits	Object	Method	Frequency	Personnel	Corrective measures	Records	Verification of CCP
Washing and sorting	Fungus, bacteria, insects, rodents, soil, foreign materials (glass, wood, stone), contamination from washing water, aflatoxin contamination	GMP and GAP regulations,	Conditions (hygiene, sanitation, temperature, humidity) of sorting area, washing water.	PRP/oPRP, Metal dedector, Microbiological analyses of water	Every batch	Operator, laborant	Design of sorting lay-out, GMP and GAP. Antifungals can be used under controlled conditions.	GAP and GMP forms, microbiological analysis report	Regularly submit GAP and GMP management log books. Application to autonomous laboratories for water analysis.
Drying	Fungus, bacteria, insects, rodents, contamination from personnel, soil, foreign material, aflatoxin contamination	Prevention of fungal growth and contamination	Time and temperature of drying	Automatic temperature and humidity controller	Every batch	Operator and technician	Prevention of direct contamination from soil, Quick drying (drying in oven or in a fluidized bed can be applied without exposion to environment), GMP, GHP	Automatic temperature and humidity controlling plot	Drying Time-Temperature form, GMP and GHP forms
		Aw product <1	Measurement of water activity	Water activity meter/analyzer
		GMP, GHP reguations	Place of drying	PRP/oPRP
Aflatoxin Analysis	Contaminated product with mycotoxin	Aflatoxin amount < 10 ppb	Amount of aflatoxin in RDCP	HPLC analyses, ready-use kits	Every batch	Technician	Analysis result, quarantina product, Irradiation technique can be used, check HACCP system.	Analysis records and log file	To verify the records apply to autonomous laboratories, analysis records, control forms, standards
Storage in bulk	Fungus, bacteria, insects, rodents, high humidity and temperature of the warehouses, re-contamination	RH<70% and T<5 °C, Aw product < 0.7. CAS, MAS, GSP regulations	Relative humidity and temperature of warehouse, water activity of product. Warehouse and storage area	Automatic humidity and temperature controller, water activity. Good storage practises	Every batch	Operator and technician	The structure of storage area and the conditions during storage need to be modified if fungal growth determined	Humidity and temperature controlling records. CAS, MAS and GSP records	Usage of a portable thermo-humidity meter to verify the automatic controllers, examine record everyday. Regularly submit storage management log book
Packaging	Contamination from/by means of packaging material	MAP and CAP regulations, no migration from package,		Automatic packaging without contamination from personnel or environment	Every batch	Results of packaging material analysis	Agreement with supplier, analysis of aflatoxin and packaging material, GMP		Packaging material control form

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[1] *Corresponding author: budak@ankara.edu.tr