De vel opm ent of HACCP pr ocedur es for

the pr oducti on of so y based foods and

thei r eval ua ti on (RP F-I II).

A.P.Gandhi

08/20/09 Gandhi 1
 Project No: 583

Time spent: 25%

08/20/09 Gandhi 2
Objectives
i.To develop HACCP procedures for
the production of different soy based
foods.
ii. To test the developed procedures
with a few soy-based foods such as
full fat soy flour, soy milk, soy paneer
(tofu),
08/20/09
soy nuts and
Gandhi
soy sprouts.3
iii. To document the developed
procedures and final report writing.

08/20/09 Gandhi 4
Technical program
The drafting of procedures
include
identification of hazards and

control measures,
determination of critical

control points,
08/20/09 Gandhi 5
preparing the decision tree,
establishing the critical

limits and marketing

procedures,

08/20/09 Gandhi 6
finding the corrective action,
responsibilities and

verification procedures ,

08/20/09 Gandhi 7
preparation of HACCP chart
documentation &
record keeping for the soy

based foods.

08/20/09 Gandhi 8
Soy products:
Flour (Full fat soy flour and
medium fat soy flour).
Soymilk and analogs (Soymilk
(Plain) and, Soy paneer) ,Bakery
products (Cookies and bread),
Soy nuts,Soy sprouts, and Soy
protein isolates .
08/20/09 Gandhi 9
Date of Start: April 2007

Date of Completion: March 2009

The technical program was

accomplished as approved.

08/20/09 Gandhi 10
 Various soy based foods like full fat soy
flour, medium fat soy flour, soy milk, soy
paneer(tofu), soy bakery products ,soy
nuts were developed besides the protein
isolates which find place in food
formulations/pharmaceutical
applications.
 These foods are to be produced with
utmost safety.

08/20/09 Gandhi 11
 The availability of safe food
improves the health of people and
is a basic human right.
 Safe food contributes to health and

productivity and provides an

effective platform for development
and poverty alleviation.
08/20/09 Gandhi 12
 The poor are the most susceptible
to ill health.
 Trends in global food production,

processing, distribution and

preparation present new challenges
to food safety.

08/20/09 Gandhi 13
 Food safety must be addressed
along the entire food chain by
measures based on sound scientific
information at both national and
international levels.
 Food safety is an essential public

health issue.
08/20/09 Gandhi 14
 Food safety programs are
increasingly focusing on a farm- to
–table approach as an effective
means of reducing food borne
hazards.
 This holistic approach to the
control of food related risks
involves consideration of every
step
08/20/09
in the chain .
Gandhi 15
 Now with the introduction of food
quality and safety systems, HACCP
has become synonymous with food
safety.
 HACCP is a tool for process control
to overcome the microbial hazards.
 The ultimate goal is improvement of
public health.
08/20/09 Gandhi 16
 It is a world wide recognized
systematic and preventive
approach that addresses biological,
chemical and physical hazards
through anticipation and prevention
rather than through end-product
inspection and testing and thereby
reducing the food borne illness.
08/20/09 Gandhi 17
 Prior to application of HACCP the
production of soy based should be
according to Codex General
Principles of Food Hygiene, the
appropriate Codex Codes of
practice and appropriate food
safety legislation.

08/20/09 Gandhi 18
Good Agricultural Practices
Primary production
Environmental hygiene:
 Should not be carried out on in
areas where the presence of
potentially harmful substances
would lead to an un acceptable
level of such substances.
08/20/09 Gandhi 19
Hygiene production of food sources:
Producers should as far as
practicable implement measures to
 Control contamination from air, soil,
water, feed stuffs, fertilizers,
pesticides, veterinary drugs or any
other agent used in primary
production.
08/20/09 Gandhi 20
 Control plant and animal health.
 Protect food sources from faecal
and other contamination.
Handling, storage and transport:
 Procedures should be in place to
sort food and food ingredients to
segregate material which is
evidently unfit for human
consumption.
08/20/09 Gandhi 21
 Dispose of any rejected material in
a hygienic manner.
 Protect food and food ingredients

from contamination by pests,

chemical, physical or
microbiological contaminants.

08/20/09 Gandhi 22
Cleaning, maintenance and personnel
hygiene at primary production:
Appropriate facilities and procedures
should be in place to ensure that
 Any necessary cleaning and
maintenance is carried out
effectively.
 An appropriate degree of personnel
hygiene is maintained.
08/20/09 Gandhi 23
Good Manufacturing Process
Establishment of Design and facilities
Location:
Establishments
They should be located away from
 Environmentally polluted areas and
industrial activities which pose
serious threat of contaminating the
food.
08/20/09 Gandhi 24
 Areas subject to flooding unless
sufficient safe guards are provided.
 Areas prone to infestation of pests.

 Areas where wastes, either solid or

liquid can not be removed

effectively.

08/20/09 Gandhi 25
Equipment:
Equipment should be located so that
it
 Permits adequate maintenance and
cleaning.
 Functions in accordance with its
intended use.
 Facilitates good hygiene practices
including monitoring.
08/20/09 Gandhi 26
Premises and rooms:
Design and lay out
 Where appropriate the internal
design and lay out of food
establishments should permit good
food hygiene practices including
protection against cross
contamination between and during
operation of food stuffs.
08/20/09 Gandhi 27
Internal structures and fittings:
 The surfaces of walls, partitions
and floors should be made of
impervious materials with no toxic
effect in intended use.
 Walls and partitions should have a
smooth surface up to a height
appropriate to the operation.

08/20/09 Gandhi 28
 Floors should be constructed to
allow adequate drainage and
cleaning.
 Ceilings and overhead fixtures

should be constructed and finished

to minimize the build up of dirt and
condensation and the shedding of
particles.
08/20/09 Gandhi 29
 Window should be easy to clean, be
constructed to minimize the build
up of dirt and where necessary be
fitted with removable and cleanable
insect proof screens.Where
necessary windows should be
fixed.

08/20/09 Gandhi 30
 Doors should have smooth, non
absorbent surfaces and be easy to
clean and where necessary
disinfect.
 Working surfaces that come into

direct contact with food should be

in sound condition, durable and
easy to clean.
08/20/09 Gandhi 31
Equipment:
 They can be adequately cleaned,

disinfected and maintained to avoid

the contamination of food.
 Equipment and containers should

be made of materials with no toxic

effect in intended use.

08/20/09 Gandhi 32
 Where necessary equipment
should be durable and movable
or capable of being
disassembled to allow for
maintenance, cleaning,
disinfections, monitoring.

08/20/09 Gandhi 33
Food control and monitoring
equipment:
 The equipment used to cook, heat
treat, cool, store or freeze should be
designed to achieve the required
food temperatures as rapidly as
necessary in the interests of food
safety and suitability and maintain
them effectively.
08/20/09 Gandhi 34
Containers for waste and inedible
substances:
 Containers for waste, by products
and inedible or dangerous
substances should be specifically
identifiable, suitably constructed
and where appropriate made of
impervious material.

08/20/09 Gandhi 35
 Containers used to hold
dangerous substances should
be identified and where
appropriate, be lockable to
prevent malicious or accidental
contamination of food.

08/20/09 Gandhi 36
Personnel hygiene facilities and
toilets:
 Where appropriate adequate means
of hygienically washing and drying
hands, including wash basins and a
supply of hot and cold water.
 Lavatories of appropriate design.

 Adequate changing facilities for

personnel.
08/20/09 Gandhi 37
Temperature Control:
 Adequate facilities should be
available for heating, cooling,
refrigerating and freezing food, for
storing refrigerated or frozen foods,
monitoring the food temperatures
and when necessary controlling the
ambient temperatures to ensure the
safety and suitability of food.
08/20/09 Gandhi 38
Air Quality and ventilation:
Adequate means of natural and
mechanical ventilation should be
provided to
 Control ambient temperatures.

 Minimize the air borne

contamination of food.
 Control odors.

 Control humidity where necessary.

08/20/09 Gandhi 39
Facilities:
Water supply
 An adequate supply of potable
water with appropriate facilities for
its storage, distribution and
temperature control should be
available where necessary to
ensure the safety and suitability of
food.
08/20/09 Gandhi 40
 Potable water should be as
specified in WHO Guidelines.
 Non potable water shall have a

separate system and shall be

identified.

08/20/09 Gandhi 41
Drainage and waste disposal:
 Adequate drainage and waste

disposal systems and facilities

should be provided.

08/20/09 Gandhi 42
Cleaning:
 Adequate facilities, suitably

designated should be provided for

cleaning the food utensils and
equipment. Such facilities should
have an adequate supply of hot and
cold potable water where
appropriate.
08/20/09 Gandhi 43
Control of operation
 Adequate time, temperature or

humidity controls.
 Food grade packaging.

 Potable water supplies.

 Maintenance of equipment.

08/20/09 Gandhi 44
Maintenance and Sanitation
 Adequate level of maintenance of

an establishment as well as efficient

practices for cleaning, waste
management and pest control.

08/20/09 Gandhi 45
Personal Hygiene
Health Status:
 People known or suspected to be

suffering from or to be a carrier of a

disease or illness likely to be
transmitted through food should
not be allowed.

08/20/09 Gandhi 46
Illness and injuries:
 Conditions which should be reported
include jaundice, diarrhea,vomiting,
fever, sore throat with fever, visibly
infected skin lesions and discharges
from the ear , eye or nose.

08/20/09 Gandhi 47
Personnel cleanliness:
 They should wear suitable

protective clothing, head covering

and footwear.Cuts and wounds
where personnel are permitted to
continue working should be
covered by suitable water proof
dressings.
08/20/09 Gandhi 48
 Personnel should always wash their
hands
-at the start of food handling
activities.
-Immediately after using the toilet.
-After handling raw food or any
contaminated material.
08/20/09 Gandhi 49
Personal Behavior:
 People engaged in food handling

activities should refrain from

behavior which could result in
contamination of food like smoking,
spitting, chewing or eating and
sneezing or coughing over
unprotected food.
08/20/09 Gandhi 50
Visitors:
 Visitors to food manufacturing,

processing or handling areas

should where appropriate wear
protective clothing and adhere to
other personal hygiene.

08/20/09 Gandhi 51
Transportation
 Method of transportation should be
such that measures are taken to
prevent any contamination or
deterioration of the product.
 Controlled environments like
chilled, frozen or stored under
specific humidity levels.

08/20/09 Gandhi 52
 Containers need to be maintained in
good condition and be easy to
clean.
 Designed specifically for food use

only.

08/20/09 Gandhi 53
Training
 All food handlers should be trained

in personal hygiene, and should be

supervised by the trained
supervisors.

08/20/09 Gandhi 54
Product information and consumer
awareness:
 The product should be
accompanied by adequate
information.
 All batches should be identified by
a batch or lot number to allow trace
ability of the commodity if required.

08/20/09 Gandhi 55
 Management commitment is
necessary for implementation of an
effective HACCP system.

08/20/09 Gandhi 56
 No relevant published data is
available on the usage of HACCP in
the production of soy-based foods
globally too.

08/20/09 Gandhi 57
 Hence efforts were made to draft
the HACCP procedures for the
production of different soy based
foods.

08/20/09 Gandhi 58
 Food safety in today’s’ world is
paramount.
 HACCP programmes go a long way
to ensuring this food safety.
 We rely on food to nourish and
sustain us.
 We want food that is appealing and
pleasurable to eat.
08/20/09 Gandhi 59
 We need food that will not cause us
injury or illness or severe cases
cause death.
 There are members of our
community- the young, the not so
young, the immunocompromised
and those who are susceptible to
allergies and intolerances that rely
on us in the food industry to supply
them with safe food.
08/20/09 Gandhi 60
 May our efforts be not in vain as we
meet this responsibility each day?

08/20/09 Gandhi 61
 PR INC IPLE S OF TH E HAC CP
SYS TEM

PRINCIPLE 1
Conduct a hazard analysis.
PRINCIPLE 2
Determine the Critical Control Points
(CCPs).
PRINCIPLE 3
Establish critical limit(s).
08/20/09 Gandhi 62
 PR IN CIPL ES OF T HE H ACCP SY STEM

PRINCIPLE 4
Establish a system to monitor control
of the CCP.
PRINCIPLE 5
Establish the corrective action to be
taken when monitoring indicates
that a particular CCP is not under
control.
08/20/09 Gandhi 63
PRINCIPLE 6
Establish procedures for verification
to confirm that the HACCP system
is working effectively.
PRINCIPLE 7
Establish documentation concerning
all procedures and records
appropriate to these principles and
their application.
08/20/09 Gandhi 64
 APP LI CA TI ON

1. Assemble HACCP team

 The food operation should assure
that the appropriate product
specific knowledge and expertise is
available for the development of an
effective HACCP plan.

08/20/09 Gandhi 65
Optimally, this may be accomplished
by assembling a multidisciplinary
team. Where such expertise is not
available on site, expert advice
should be obtained from other
sources.

08/20/09 Gandhi 66
 The scope of the HACCP plan
should be identified. The scope
should describe which segment of
the food chain is involved and the
general classes of hazards to be
addressed (e.g. does it cover all
classes of hazards or only selected
classes).
08/20/09 Gandhi 67
2. Describe product
A full description of the product should be
drawn up, including relevant safety
information such as: composition,
physical/chemical structure (including
Aw, pH, etc.), microcidal/static treatments
(heat-treatment, freezing, brining,
smoking, etc.), packaging, durability and
storage conditions and method of
distribution.
08/20/09 Gandhi 68
3. Identify intended use
The intended use should be based on
the expected uses of the product by
the end user or consumer. In
specific cases, vulnerable groups of
the population, e.g. institutional
feeding, may have to be considered.

08/20/09 Gandhi 69
4. Construct flow diagram
The HACCP team should construct
the flow diagram. The flow diagram
should cover all steps in the
operation. When applying HACCP
to a given operation, consideration
should be given to steps preceding
and following the specified
operation.
08/20/09 Gandhi 70
5. On-site confirmation of flow diagram
The HACCP team should confirm the
processing operation against the
flow diagram during all stages and
hours of operation and amend the
flow diagram where appropriate.

08/20/09 Gandhi 71
6. List all potential hazards associated with
each step, conduct a hazard analysis,
and consider any measures to control
identified hazards.
The HACCP team should list all of the
hazards that may be reasonably
expected to occur at each step from
primary production, processing,
manufacture, and distribution until the
point of consumption.
08/20/09 Gandhi 72
The HACCP team should next
conduct a hazard analysis to
identify for the HACCP plan, which
hazards are of such a nature that
their elimination or reduction to
acceptable levels is essential to the
production of a safe food.
08/20/09 Gandhi 73
7. Determine Critical Control Points
 There may be more than one CCP at

which control is applied to address

the same hazard. The determination
of a CCP in the HACCP system can
be facilitated by the application of a
decision tree which indicates a
logic reasoning approach.
08/20/09 Gandhi 74
Application of a decision tree should
be flexible, given whether the
operation is for production,
slaughter, processing, storage,
distribution or other. It should be
used for guidance when
determining CCPs.
08/20/09 Gandhi 75
8. Establish critical limits for each
CCP .
 Critical limits must be specified and

validated if possible for each

Critical Control Point. In some
cases more than one critical limit
will be elaborated at a particular
step.
08/20/09 Gandhi 76
 Criteria often used include
measurements of temperature, time,
moisture level, pH, Aw, available
chlorine, and sensory parameters
such as visual appearance and
texture.

08/20/09 Gandhi 77
9. Establish a monitoring system for
each CCP.
 Monitoring is the scheduled
measurement or observation of a
CCP relative to its critical limits.
 The monitoring procedures must be
able to detect loss of control at the
CCP.

08/20/09 Gandhi 78
 Further, monitoring should ideally
provide this information in time to
make adjustments to ensure control
of the process to prevent violating
the critical limits.
 Where possible, process
adjustments should be made when
monitoring results indicate a trend
towards loss of control at a CCP.
08/20/09 Gandhi 79
10. Establish corrective actions .
 Specific corrective actions must be

developed for each CCP in the

HACCP system in order to deal with
deviations when they occur.

08/20/09 Gandhi 80
 The actions must ensure that the
CCP has been brought under
control. Actions taken must also
include proper disposition of the
affected product.
 Deviation and product disposition

procedures must be documented in

the HACCP record keeping.
08/20/09 Gandhi 81
11. Establish verification procedures .
 Verification and auditing methods,
procedures and tests, including random
sampling and analysis, can be used to
determine if the HACCP system is
working correctly.
 The frequency of verification should be
sufficient to confirm that the HACCP
system is working effectively.

08/20/09 Gandhi 82
12. Establish Documentation and
Record Keeping .
 Efficient and accurate record
keeping is essential to the
application of a HACCP system.
 HACCP procedures should be
documented.
 Documentation and record keeping
should be appropriate to the nature
and size of the operation.
08/20/09 Gandhi 83
 TRA INI NG

 Training of personnel in industry,

government and academia in
HACCP principles and applications,
and increasing awareness of
consumers are essential elements
for the effective implementation of
HACCP.

08/20/09 Gandhi 84
 As an aid in developing specific training
to support a HACCP plan, working
instructions and procedures should be
developed which define the tasks of the
operating personnel to be stationed at
each Critical Control Point.
 Cooperation between primary producer,
industry, trade groups, consumer
organizations, and responsible
authorities are of vital importance .
08/20/09 Gandhi 85
 

08/20/09 Gandhi 86
  

08/20/09 Gandhi 87
 

08/20/09 Gandhi 88
 Applicat ion of HAC CP in S oy
foods

 Various soy-based foods were prepared

with and with out HACCP protocols
using the procedures developed at this
Center since 1979.
 The products were full fat soy flour,
medium fat soy flour, soymilk, soy
paneer(Tofu), soy bakery products
(biscuits& bread), soy nuts, soy sprouts
and protein isolates.
08/20/09 Gandhi 89
 Material s and Methods

 The soybean variety JS 335 was

obtained from the Institute Farm.
 It was cleaned thoroughly and made

free from all the dirt, stubbles and

other foreign matter.

08/20/09 Gandhi 90
 It was stored in airtight containers
till further use.
 Different soy based foods were

prepared following the methods

developed at this center.

08/20/09 Gandhi 91
 FAO/WHO (2006) guidelines were used
for the preparation of HACCP plans.

 AOAC (1990) methods were used for

analyzing various chemical constituents
and APHA (1984) recommended methods
were used for microbiological
examination of the products.

08/20/09 Gandhi 92
 Full Fat S oy flo ur

08/20/09 Gandhi 93
 Table1.Product description
1. Product name Full Fat Soy flour
2. Important product Aw < 0.5;FFA < 1%; Total
characteristics of end product microbial counts < 50000/g
3. How the product is to be Normally fortified with other
used cereals/millets/pulses at 10-
15% level in the preparation of
traditional recipes.

4. Packaging Sealed polythene bags/

hermetically sealed metal
containers.
08/20/09 Gandhi 94
 5. Shelf-life One month at normal retail
shelf temperatures.
6. Where the product will be Retail, institutions and food
sold service. Could be consumed
as a health food.
Required to ensure product
7. Labeling instructions
safety.

8. Special distribution control

No physical damage, excess
humidity or temperature
extremes.

08/20/09 Gandhi 95
 Table 2.P roduct ingr edi ents and incoming
mater ial
Soybeans Packaging Dry ingredients Water
material
2.Receiving P 3. Receiving P
1. Receiving P 7. Storing B C P
4. In taking
6.Storing B C P
5.Storing B P 10. Dumping
9.Inspecting B P

8. Cleaning P

11. De hulling P 13.

Chlorinating
12. Soaking B C 17.Filling C P
14. Blanching B C
18.Weighing B
15.Drying B P C
16. Milling B P C 19.Closing/sealin
gB

20.Inspecting B P
08/20/09 21. Labeling B
Gandhi 96
22. Storing B
Table 3.Un add resse d Haz ards:

Unaddressed hazard Identified methods of

addressing the hazard
Soybeans could contain Up stream (farm level)
pesticide residues programs such as
A: Training persons who
apply pesticides.
B: Purchasing registered
pesticides for growers.
C: Auditing growers
application of pesticides and
records there of.
D: Requiring periodic
pesticide residual analysis
08/20/09 Gandhi 97
reports.
 Table 4.HA CCP P lan
 

Process Hazard Critical Monitoring Deviation HACCP

step description limits procedure procedures records

De Inefficient de Less On line check Line Operator

hulling hulling may than of the sample operator to log book
cause the 0.1% adjust the
contamination clearance
of the product of the de
with the huller
microorganis drums.
ms.

08/20/09 Gandhi 98
 Process Hazard Critical Monitoring Deviation HACCP
step description limits procedure procedures records

Blanching/ In Cook the Check the Operator Operator

cooking adequate splits as quality of should logbook.
heat specified in splits for adjust the
treatment the urease test time and
scheduled temperatur
process e as per
(under the
pressure/o authorized
pen vessel contingenc
boiling) y plan and
to inform
the QC.

08/20/09 Gandhi 99
  

Process Hazard Critical Monitoring Deviation HACCP

step description limits procedure procedures records

Drying Improper The Check the If moisture Operators

(Sun/mech drying moisture moisture content is log book.
anical) content content as greater the
should be per the splits may
less than guidelines. be dried
8%-10%. again and
inform QC

08/20/09 Gandhi 100

  

Process step Hazard Critical Monitoring Deviation HACCP

description limits procedure procedures records

Packaging Over filling, Max fill On line Line Operators

and sealing improper weight as check to operator to log book and
gauge specified in reject over adjust the quality
polythene the and under settings. control
and scheduled filled bags report.
improper process. and
sealing Proper improperly
sealing sealed bags.
leaving
recommende
d space.

08/20/09 Gandhi 101

 Table 5.HAC CP for gener al activities:
 

Stage Activity Control activity

Raw material harvest Liaison with the farmers Specifications of grain
for unit operations like quality are required.
harvesting, threshing Rejection of under sized
and winnowing. seeds.

Transport in sacks to Correct sacking and

Raw material transport drying area handling.

Sampling and routine Correct sampling

Raw material inspection inspection. methods, training and
inspection methods.

Preparation of seeds Cleaning, grading, Training operators for

dehulling, conditioning equipment, preventing
and blending. insect infestations,
08/20/09 Gandhi check for 102moisture
content.
 Stage Activity Control activity

Milling and sieving, and Separation of Training in hygiene,

dehulling components of seeds implementation of
cleaning, and
assessment of product
quality.

Packaging Filling in to containers

Establish specifications
and sealing.
for labels and fill
weights.

08/20/09 Gandhi 103

 Impl ementa ti on of HACCP

Receiving soybeans (CCP-1):

Soybeans must come from

approved dealers. At the time of

its receipt it must be
accompanied with its complete
quality certificate and
microbiological assessment
reports.
08/20/09 Gandhi 104
 The certificates should indicate
the moisture content of the beans,
degree of foreign materials and the
microorganisms present (number
of colonies), insects etc as
compared to the upper approved
standards of BIS/ISO.
08/20/09 Gandhi 105
 At the time of receipt, visual control of
soybeans must be carried out to find out
the contaminants if any.
Further more the proximate composition

of the beans must be established with

reference to its macro and micronutrients.
Defective beans mean that the soy flour
will be most likely unsafe for the
consumption.
08/20/09 Gandhi 106
 Storage of soybeans in silos (CCP-4):
The temperature (<20oC) and the relative

humidity (<65%) during the storage must

be low.
They should be recorded at regular

intervals. If any deviation from the safer

limits, must be immediately rectified.
When soybean is stored for a long

period, microbiological analysis should be

carried out.

08/20/09 Gandhi 107

 Receiving secondary materials
(greasing, detergents, insecticides,
pesticides and sacs) (CCP-2):
These materials must be procured

from the approved suppliers with

quality certificates.
These materials must be suitable

for using them with food items.

08/20/09 Gandhi 108

 No contamination must come
from the packaging materials.
If these materials do not
comply with the standard
specifications, must be
returned to the suppliers and a
new order should be placed
with other suppliers.

08/20/09 Gandhi 109

 Storage of secondary materials
(CCP-3):
The temperature and relative

humidity during storage must

be below 20oC and 65%
respectively.
The place should be air-
conditioned.
08/20/09 Gandhi 110
 The temperature and RH
should be continuously
recorded and corrective actions
must be undertaken whenever
any deviation occurs.

08/20/09 Gandhi 111

 Application of anti insect
methods (CCP-5):
Any chemicals used during

storage along with the

soybeans should comply with
the safety legislations.
The quantity should be with in

the prescribed concentrations.

08/20/09 Gandhi 112

 Cleaning & grading of soybeans
(CCP-6):
All the physical contaminants

should be removed.
They should be graded.

Only sound soybeans should

be taken for processing.

08/20/09 Gandhi 113

 Removal of stones:
The stones, metals and dust must

be removed from the soybeans so

that the final product will comply the
quality standards as prescribed by
BIS/ISO.
Weighing:
The soybeans are weighed and

passed through a magnetic system

so that the magnetic materials are
08/20/09 removed. Gandhi 114
 De hulling (CCP-7)
Inefficient de hulling may cause the

contamination of the product with

the microorganisms. Less than 0.1%
hulls are allowed. Hence an efficient
dehulling should be used in order to
prevent the contamination with the
microorganisms.

08/20/09 Gandhi 115

 Blanching/cooking (CCP 8)
In adequate heat treatment results in
the poor quality of the product.
Cook the splits as specified in the
scheduled process (under
pressure/open vessel boiling) to
minimize the anti nutritional factors.
Check the quality of splits for
urease test.
08/20/09 Gandhi 116
 Drying (Sun/mechanical)(CCP 9)
Improper drying will result in
the poor quality product. Hence
proper drying methods are to
be adopted for reducing the
moisture content to the safe
level( 8-10%).

08/20/09 Gandhi 117

 Milling (CCP-10):
The grinding is done in a
burr/hammer mill.
The clearance between the burrs

should be adjusted so that the flour

must be having particle size <140
micrometers.
 Similarly with the hammer mill, the

sieve below the grinding system

must allow flour particles less than
08/20/09 140 micrometers.
Gandhi 118
 The sieves should be of SS. The
temperature during grinding should
not rise too much, which affects the
quality of the flour
Normally a temperature rise of less

than 5oC is desirable.

 So arrangements must be made to

maintain the temperature while

grinding.

08/20/09 Gandhi 119

 Packaging (CCP-11):
During packaging the flour

can possibly be contaminated

with the microorganisms
causing quality deterioration.
Hermetic sealing and upright

position of the packaging

material can avoid this
deterioration.
08/20/09 Gandhi 120
 There should not be any migration
of the low molecular weight
substances from the packages.
Further more contamination can

take place from foreign materials

like insects and rodents that
accidentally happen to be packed
with the flour.
The personnel should comply with

the GMPs.
08/20/09 Gandhi 121
 Storage of full fat flour (CCP-12):
Both the temperature and relative

humidity must be below 20oC and

65% respectively.
They should be recorded and
corrective actions must be taken
when deviating.
When the flour is stored for a long

period, microbiological analysis is

required.
08/20/09 Gandhi 122
 Metal detector (CCP-13):
The packed product passes
through a metal detector.
The product is then checked

for its weight and placed in

boxes (secondary packaging).
The boxes are placed on the

pallets and the packets are

wrapped with film.
08/20/09 Gandhi 123
 Table 6.Q uality S tandar d E xpected

Composition:
Protein: a minimum of 35%
Fat: a minimum of 18%
Crude Fiber: a maximum of 4%
Ash: a maximum of 6.5%
Moisture: a maximum of 10%

Physical parameters:
Granulation: 90% minimum pass thru US sieve
200(0.074 mm)

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 Microbiology:
Total plate count: 20,000/g max
Total coli forms: 100/10g max
Salmonella: Negative/100g
E.coli:
Negative/100g
Staphylococcus:
100/10g max
Yeast:
100/10g max
Mold:
100/10g max.

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 Protein solubility: PDI 20-80%
TI: less than 75% of original.
Urease activity: Nil
Available lysine: Min 5.5g/6g N

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 Sensory parameters:
Color: Creamy to yellow
Odor: Less beany
Taste:
Nutty
Defects:
Insect parts:
Total absence.
Foreign material:
Total absence
Black specks:
. Total absence

08/20/09 Gandhi 127

 Tab le 7 . Quality ass es sment of the Full Fat Soy
Flo ur

Quality standard With out HACCP With HACCP

expected
Composition:
Protein: a minimum of 35% 40%
35%
Fat: a minimum of 17% 20%
18%
Crude Fiber:a maximum
of 4% 5.2% 3.8%
Ash: a maximum of 6.5% 5.4% 6.3%
Moisture: a maximum of
10% 10% 8%
Physical parameters:
Granulation: 90% 75% 95%
minimum pass thru US
sieve 200(0.074 mm)
08/20/09 Gandhi 128
.
 Quality standard With out HACCP With HACCP
expected

Microbiology:
Total plate count: 10,000/g
20,000/g max 50,000/g
Total coli forms: Nil
100/10g max 120/10g
Salmonella:
Negative/100g Nil
10/100g
E.coli
Negative/100g Nil
15/100g
Staphylococcus:
100/10g max Nil
Yeast: 100/10g max 135/10g Nil
Mold: 100/10g max. 123/10g Nil
110/10g
08/20/09 Gandhi 129
 Quality standard With out HACCP With HACCP
expected

Protein solubility:
PDI 20-80% 25% 75%
TI: less than 75% of
original. 50% 80%
Urease activity: Nil
Nil Nil
Available lysine: Min
5.5g/6g N
4.2g/6gN 6.2g/6gN

08/20/09 Gandhi 130

 Quality standard With out HACCP With HACCP
expected
Sensory parameters:
Color: Creamy to
Yellow Creamy
yellow
Odor: Less beany
Taste: Nutty Beany Less beany
Nutty Nutty
Defects:
Insect parts: Total
absence. Absent Absent
Foreign material: Total Absent Absent
absence.

08/20/09 Gandhi 131

 Conclusion/Output:
HACCP procedures were developed for making
soy based foods (Full Fat Soy flour,Medium Fat
Soy Flour,Soy Milk, Soy Paneer, Soy Bakery
Products, Soy Nuts, Soy Sprouts and Soy
Protein Isolates) with utmost quality and safe for
use.
A proactive approach was suggested to
controlling the hazards through out the supply
chain of soy based foods production.

08/20/09 Gandhi 132

More flexibility in addressing identified hazards is
given in the proposed HACCP program, which
permits the soy food processors to select the
appropriate and economical methods of control.

Quality control managers are responsible for the

design and maintenance of the suggested
protocols with government agencies auditing
compliance.

08/20/09 Gandhi 133

 Summary Table:
Develop HACCP procedures for the
production of different soy based foods-
Accomplished.
Test the developed procedures with a few
soy-based foods such as full fat soy flour,
soy milk, soy paneer (tofu), soy nuts and
soy sprouts.-Evaluated.
Document the developed procedures and
final report writing- Documented.
08/20/09 Gandhi 134
 Approximate expenditure incurred in
the project (Rs): 3, 10,000.

08/20/09 Gandhi 135

 Recommendations:
The HACCP procedures developed
may be used for the production of
different soy based foods with Good
Manufacturing Processes and Good
Food Hygiene Practices
recommended by the Codex
Alimanatarius Commission/FAO for
maintaining the safety and quality of
the products.
08/20/09 Gandhi 136
 Acknowledgments:
Gratefully acknowledges the
cooperation received from the
Director, CIAE; Project Director and
staff of SPU Center and every one
of you in accomplishing the project
and also during my entire service
period(1979-2009) in general.

08/20/09 Gandhi 137

 Papers Published
i. Gandhi, A.P. (2008) Development of HACCP procedure for the production of
Full fat Soy Flour, International Food Research Journal 15(2), 141-154.
ii. Gandhi, A.P. (2008). Production of Soy Nuts using the Hazard Analysis
Critical Control Point (HACCP). Asian journal of Food and Agro industry, 1
(3),137-154.
iii. Gandhi, A.P. (2009). Quality of Soybean and its food products-a review.
International Food Research Journal,16(01),11-19.
iv. Gandhi, A.P. (2009). Development of HACCP protocols for the production of 
soy milk, Accepted for publication in Asian journal of Food and Agro industry .

Papers presented
Gandhi, A.P (2008) Development of HACCP protocols for the production of
soy milk, presented in the ISPUC, held at CIAE, Bhopal, December 10-
14,2008.
Gandhi, A.P (2008) Use of Hazard Analysis Critical Control Point Principles in
Quality Control of Soy Foods(Theme paper) presented in the ISPUC, held at
CIAE, Bhopal, December 10-14,2008.

08/20/09 Gandhi 138

 THANK YOU

08/20/09 Gandhi 139