1. Sugarcane growing (CCP and CP) |
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Quality |
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CP |
M |
Fungal, bacterial, and viral diseases of sugar cane |
Use of biocides |
Use of biocides and pesticides the correct time |
Use at the correct time and according to GAP |
Instruction of personnel |
Agronomist |
CP |
C |
Lack of soil nutrients |
Use of fertilizers |
Soil analysis for nutrients (specialized laboratory) |
Use at the correct time and according to manufacturer specifications |
Instruction of personnel |
Agronomist |
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Safety |
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CCP |
C |
Incorrect use of biocides (dose, type, application time) |
GAP |
Specific chemical analysis |
Proper use according to OPAS (2006)Organização Pan-Americana da Saúde [OPAS]. 2006. Food hygiene: basic texts = Higiene dos alimentos: textos básicos. Available at: http://www.paho.org/bra/index.php?option=com_docman&task=doc_view&gid=286&Itemid=965 [Accessed Jan 26, 2017] (in Portuguese). http://www.paho.org/bra/index.php?option...
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Instruction of personnel |
Agronomist |
2. Sugar cane harvesting (CCP and CP) |
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Quality |
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CP |
M |
Microbiological contamination or injury |
Use of biocides |
Analysis of sugarcane juice (reduced sugar concentration) |
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Instruction of personnel |
Trained personnel |
CP |
M |
Bacterial contamination by insects |
Use of antimicrobiological agents |
Analysis of sugarcane juice (acidity) |
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Instruction of personnel |
Trained personnel |
CP |
P |
Foreign matter from the soil (stones, metal compounds) |
Sugar cane harvesting 10 cm above the soil |
Visual inspection during harvesting |
Regulation of harvest machine and personnel training |
Regulation of harvest machine an instruction of personnel |
Trained personnel |
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Safety |
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CCP |
C |
Formation of furfural, 5-HMF, an PAHs |
Avoid sugar cane burning before manual harvesting |
Chemical analysis of pure (not aged) cachaca using HPLC |
Furfural + 5-HMF ≤ 5 mg L-1
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Abolishment of sugar cane burning before harvesting |
Quality control manager |
CCP |
C |
Pesticide resid ues |
GAP and more care during harvesting |
Establishment of the last day o pesticide spraying, use of specific chemical analysis |
Proper use according to OPAS (2006)Organização Pan-Americana da Saúde [OPAS]. 2006. Food hygiene: basic texts = Higiene dos alimentos: textos básicos. Available at: http://www.paho.org/bra/index.php?option=com_docman&task=doc_view&gid=286&Itemid=965 [Accessed Jan 26, 2017] (in Portuguese). http://www.paho.org/bra/index.php?option...
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Delay of harvesting date |
Agronomist |
3. Sugarcane transportation (CP) |
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Quality |
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CP |
NA |
Sugar loss by exudation |
Rapid transportation |
Chemical analysis |
Immediate transportation |
Instruction of personnel |
Trained personnel |
CP |
M |
Increase in microbial contamination and oxidation |
Rapid transportation, protection against excessive light and heat |
Chemical analysis |
Immediate transportation, protection against excessive light and heat |
Rejection of contamined sugar cane |
Quality control manager |
CP |
P |
Foreign matter in sugar cane (residues from the soil, dust) |
Adequate harvesting |
Visual control |
Excessive foreign matter and residues |
Sugar cane washing |
Trained personnel |
4. Milling (CP) |
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Quality |
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CP |
NA |
Sugar loss in the bagasse |
Mill regulation, bagasse soaking in sequential mills |
Chemical analysis of bagasse |
Sugar loss ≤ 35 % |
Bagasse soaking in sequential mills |
Quality control manager |
CP |
NA |
Must oxidation |
Shorter period between harvesting and extraction |
Chemical analysis of must |
pH 5.4-5.8; acidity 2.0-3.0 g H2SO4/L |
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Quality control manager |
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Safety |
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CP |
C |
Grease contamination of mill |
Adequate amount of grease |
Visual inspection |
Abolishment of excessive grease |
Mill maintenance |
Trained personnel |
CP |
P |
Foreign matter in the must from the equipment (metal compounds, screws) |
Mill cleaning and use of GMP during juice extraction |
Visual inspection |
Mill regulation |
Mill maintenance |
Trained personnel |
CP |
P |
Foreign matter in the must from harvesting (sugar cane parts, leaves, soil) |
Sieving after juice extraction |
Visual inspection |
Removal of most harvesting and plan residues |
Adoption of an efficient settling system |
Trained personnel |
CP |
M |
Must contamination due to inadequate cleaning |
Adequate CIP (crusher, settling system, sieves, and pipelines) |
Visual inspection |
Control of mill system cleaning |
Daily disinfection of equipment |
Trained personnel |
5. Fermentation (CCP and CP) |
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Quality |
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CP |
M, C |
Presence of chlorine in water to adjust must concentration |
Filtration and dechlorination |
Analysis of water |
NA |
Use of filters and demineralization treatment |
Quality control manager |
CCP |
M, C |
n-butanol and sec-butanol formation |
Avoid bacterial contamination and long interval before distillation |
NA |
NA |
Control of distillation process |
Quality control manager |
CCP |
M, C |
Acetic acid formation by acetic bacteria |
Avoid equipment and pump contamination, use of GMP (hygiene and aseptic procedures) |
Analysis of cachaça using potentiometer and titration |
Maintenance of pH 4.0-4.5 and acidity 2.5-5.0 g H2SO4/L, long interval before distillation |
Control of distillation process |
Quality control manager |
CCP |
C |
Ester and aldehyde excessive formation |
Use of proper yeast, avoidance o multiple yeast reuse |
NA |
NA |
Control of distillation process |
Quality control manager |
CCP |
C |
Higher alcohol formation |
Use of proper yeast, control of fermentation temperature, pH, an excessive oxigenation |
NA |
Maintenance of pH ≥ 4.0; temperature ≤ 32 °C, long interval before distillation |
Rejection of batch |
Quality control manager |
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Safety |
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CCP |
C |
Ethyl carbamate precursor formation (citruline and arginine) |
Avoidance of excessive nitrogen fertilization, high temperatures, and nitrogen yeast supplementation, use of proper yeast and GMP |
NA |
NA |
Control of distillation process |
Quality control manager |
CCP |
C |
Methanol formation |
Presence of pectine from bagasse - use of sieve with smaller openings, removal of decanted and floating residues from juice |
Visual inspection of residues |
Visual inspection |
Control of distillation process |
Quality control manager |
6. Distillation (CCP and CP) |
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Quality |
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CP |
C |
Dimethyl sulfide formation, affecting sensory quality |
Use of copper equipment for distillation |
Sensory analysis of cachaça using GC-MS |
Sensory acceptance of cachaça: DMS ≤ 2.48 ppm |
Storage or aging process |
Trained personnel |
CCP |
C |
High copper content in the final product |
Control of pot still cleaning |
Chemical analysis |
Cu ≤ 5 mg L-1
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Rejection of batch |
Quality control manager |
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Safety |
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CCP |
C |
“Heads” components in excess (acetaldehyde, esters, and methanol) |
Control of “heads” cut volume (about 2 % of pot still volume) |
Analysis of cachaça using GC-FID |
Aldehydes ≤ 30 mg 100 mL-1 AA; ester ≤ 200 mg 100 mL-1 AA; methanol ≤ 20 mg 100 mL-1 AA |
Redistillation of cachaça cutting more the “heads” fraction |
Quality control manager |
CCP |
C |
“Tails” components in excess (acetic acid and furfural) |
Control of “tails” cut volume |
Analysis of cachaça using GC-FID |
Acetic acid ≤ 150 mg 100 mL-1 AA; furfural + 5HMF ≤ 5 mg 100 mL-1 AA |
Redistillation of cachaça cutting more the “tails” |
Quality control manager |
CCP |
C |
Furfural formation |
Control of sugar content in the final wine (at the end of fermentation), control of presence of yeast residues |
Analysis of cachaça using HPLC |
Furfural + 5HMF ≤ 5 mg 100 mL-1 A |
Redistillation of cachaça cutting more the “tails” |
Trained personnel |
CCP |
C |
Acrolein formation (from pot still or fermentation) |
Avoidance of high temperature during distillation, control of “heads” cut volume (about 2 % of pot still volume) |
Analysis of cachaça using HPLC |
Acrolein ≤ 5 mg 100 mL-1 AA |
Redistillation of cachaça
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Quality control manager |
CCP |
C |
Presence of heavy metals |
Use of stainless steel tanks |
Analysis of metals using AAS |
NA |
Rejection of batch |
Quality control manager |
CCP |
C |
Ethyl carbamate formation |
Control of distillation process, temperature, in case of slow distillation, use reflux system in the pot still |
Analysis of cachaça using GC-MS |
EC ≤ 210 Mg L-1
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Rejection of batch |
Quality control manager |
7. Aging process (CCP and CP) |
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Quality |
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CP |
M |
Microbiological contamination caused by used wooden barrels |
Cleaning wooden barrels before use |
Microbiological analysis |
Absence of yeast, mold, and bacteria |
Wooden barrel rewashing |
Trained personnel |
CP |
C |
Acetic acid excessive formation |
Use of well preserved wooden barrels, avoidance of long aging period |
Analysis of cachaça using GC-FID |
Acetic acid ≤ 150 mg 100 mL-1 AA |
Rejection of batch |
Quality control manager |
CP |
C |
Reduction of ethanol content |
Control of temperature and humidity of warehouse |
Ethanol measurement |
Minimum of 38 % ABV |
Rejection of batch |
Trained personnel |
CCP |
C |
Adverse chemical compounds from wooden barrels |
Use of proper wood species |
Chemical analysis |
Certified and proper wooden barrels |
Rejection of barrel |
Quality control manager |
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Safety |
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CCP |
C |
HPA and furfural formation due to intensive toasting process |
Control of toasting intensity and temperature during cooperage, wash wooden barrel before reusing it |
Chemical analysis |
Carbonization of wood |
Rejection of barrel |
Trained personnel |
8. Filtration and Standardization (CP) |
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Quality |
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CP |
C |
Turbidity caused by excessive quantity of minerals in water |
Use of specific water filters for mineral removal |
Chemical analysis |
Visual turbidity in standardized cachaça
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Standardized cachaça filtratio using a specific filter for mineral removal, cold filtration |
Trained personnel |
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Safety |
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CP |
C |
Water contamination with heavy metals |
Use of specific water filters for heavy metal removal |
Chemical analysis using ionic chromatography |
Pb ≤ 200 μg L-1 and As ≤ 100 μg L-1
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Standardized cachaça filtration using a specific filter for heavy metal removal |
Quality control manage |
9. Bottling (CP and CCP) |
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Quality |
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CP |
C |
Presence of detergent residues |
Control of washing system and water flushing |
Avoidance of detergent residues by rinsing several times |
No detergent residues |
Rinsing several times |
Trained personnel |
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Safety |
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CP |
P |
Physical contamination (glass, machine parts, insects) |
Use of visual control and GMP in bottling area |
Visual control |
No physical contaminants inside the bottle |
Rejection of contamined bottle |
Trained personnel |