Flour Mills Safety
Flour Mills Safety
Flour Mills Safety
What Is Wheat?
Wheat is a raw agricultural commodity. Wheat grain is a staple food used to make flour for leavened, flat and steamed breads, cookies, cakes, pasta, noodles and couscous, and for fermentation to make beer, alcohol, vodka or bio-fuel. The husk of the grain, separated when milling white flour, is bran. During growth, harvest, and distribution it is naturally contaminated with microorganisms from numerous sources, including soil, air, water, birds, rodents and insects. While milling will remove most (more than 90 percent) of the microbes but the resulting flour is still a raw agricultural commodity. There is no kill step in milling that will further reduce the level of microbes in flour.
http://www.x-cd.com/opmillers/PaperSperber.pdf
83% 14.5 %
2.5%
Types Of Wheat
Hard wheats include the strong wheats of Canada (Manitoba) and the similar hard red spring (HRS) wheats of the US. They yield excellent bread-making flour because of their high quantity of protein ranges 1215 % mainly in the form of Wet gluten (29-39%). Medium type is used for general purposes like bun, rolls and donuts having protein 9-12 % with wet gluten 27-30 %. Soft wheats, the major wheats grown in the UK, most of Europe, and Australia, result in flour producing less attractive bread than that achieved from strong wheats. The loaves are generally smaller, and the crumb has a less pleasing structure. Soft wheats, however, possess excellent characteristics for the production of flour used in cake & biscuit manufacture.
Sampling
After passing the preliminary tests, the composite sample is divided into two portions of approximately 1,350 gm each: the work sample and the file sample. The work sample is used to determine the moisture and all grading factors. The file sample is maintained in a moisture-proof container at the lab. and is stored in a locked compartment after the inspection is completed. In the event there is any question regarding the quality of the grain, the file sample is available for review. A Boerner Divider is used in the laboratory to break down the representative sample into smaller sized portions for factor determinations. Each time grain passes through the divider, it divides the sample into two approx. equal portions.
Sample Inspection
During sampling, the inspector periodically examines the samples collected in the lab. for the objectionable odors. A portion of the wheat from the collection box is transferred into a sieve pan & smells the grain for unusual or unnatural odors. Then, the inspector examines the sample for the insect & infestation. The inspector sieves the entire sample and performs a visual examination for live insects that fall through the sieve into the bottom pan.
Dockage
Carter Dockage Tester Large Material
Light Material
Small Material
This material consists of all matter that is lighter than, larger than, and smaller than wheat. The material removed by a dockage tester is readily separated
Damage Kernels
Damaged Kernels Kernels, pieces of wheat kernels, & other grains that are badly ground-damaged, badly weather-damaged, diseased, frost-damaged, germ-damaged, heat-damaged, insect-bored, mold-damaged, sproutdamaged, or otherwise materially damaged Damaged kernels is a gradedetermining factor and is composed of two categories: 1)heat damage 2)total damage. Heat-damaged kernels are reported separately from all other types of kernel damage but are included in the total damage.
Insect damaged
Acceptable
Definition
Effect on Wheat/Milling
68 1-2 %
Bulk density measure; weight of a specific volume of grain Kernel defects due to heat, germ, insect, frost, sprouting
Foreign Material
0.5%
All non-wheat material that remains in a dockage and shrunken and broken kernel free sample
Broken or shrunken enough to go through NO.2 sieve in carter dockage tester All non-wheat material that can be removed from a sample using approved procedures Indicator of sprout damage and 300 Sec Minimum flours ability to set up
0.5%
Provides rough estimate of potential flour yield Affects the appearance of flour, increases, ash, decreases yield, or decreases sanitary quality Wheat must be cleaned of foreign material before milling into flour, if not, foreign material can decrease the quality of flour Must be removed before milling; sold at a reduced cost in comparison to flour Wheat must be cleaned of dockage before it is milled into flour Falling number <250 results in gummy bread and flour unable to thicken in gravies or soups Kernel weight, along with moisture effects protein
Foreign Other Other Damaged matter grains food wheats (% by wt.) grains (% by wt.) (% by wt.) (% by wt.) 1.0 1.6 5.0 1.0
Immature Weevilled Grains shriveled & Broken Grains (% by wt.) (% by wt.) 2.0 1.0
II
1.0
3.0
15.0
2.0
4.0
4.0
3.0
III
1.0
6.0
20.0
4.0
6.0
10.0
6.0
IV
1.0
8.0
20.0
5.0
10.0
10.0
10.0
Wheat
14.5%
1.5% 0.5% 68 Kg/hl 5.0% 2.0% 6.0% 1.5% 0.1% 0.05%
Durum Wheat
14.5%
1.5% 0.5% 70 Kg/hl 6.0% 3.0% 4.0% 2.5% 0.1% 0.05%
Raw Material Packing Material Raw wheat Paper & Polythene bags Water (Municipal)
2. 3. 4. 5.
Milling Process
After the wheat was tempered for a couple of hours in the tempering bins, the wheat passes through a scourer and aspirator in order to remove any mud formed (Anon. 2004b).CCP Reduction in micro flora by rubbing grain to grain friction and grain to rough wall and remainder is removed by aspiration process. After this last cleaning section, the wheat goes through to the first break roller and first break scale. During the milling process, the endosperm is separated from the bran and the germ by breaking the kernel into smaller fragments (Mousia and Pandiella 2004) These break rolls are fluted rolls that was designed to break each grain into three parts the endosperm, germ and bran. OPRP-Coarse bran & Germ removal A continuous process of grinding, conveying and sifting takes place whilst the endosperm is sent through reduction rolls, scales and sifters in order to reduce bran quantity and sizes to produce the final safe and quality flour product. The bran and wheat germ were also sifted into different streams and separated by sieves so that when the milling process is complete, these products are also separated and these risky portion are transferred for animal feed products.
After the wheat was tempered for a couple of hours in the tempering bins, the wheat passes through a scourer and aspirator in order to remove any mud formed and matter (Anon. 2004b).OPRP In Scourer process, micro flora is reduced by rubbing grain to grain friction and grain to rough wall and remainder is removed by aspiration process
Debranning Micro Flora Reduction Process-OPRP The aleurone layer refers to the most inner part of the bran layers
closest to the endosperm was removed with the bran layers because it is very difficult to separate in milling processes. Debranning, removes the layers from the wheat grain from the outside inwards which means that the aleurone layer can remain attached to the endosperm (Mousia and Pandiella2004). Advantages of the debranning system are: Improvements in the flour ash and colour Improved flour quality, more value-added food since the aleurone is used, Debranning reduces stress on the milling process, increases yield and reduces bran size (Mousia and Pandiella 2004). This system has proved that it efficiently removes the bran from the wheat kernel therefore improving the flour quality and reduce contamination lesser degree. The bread quality is affected in terms of colour, volume and texture (Mousia and Pandiella 2004). The presence of bran in the final product therefore can have a negative effect on the flour shelf life and stability during storage. (Mousia and Pandiella 2004).
Feed Screen
Abrasion Roll
Blower
Screw Feeder
Suction Fan
Finished Flour
The result of the milling process is production of different types of flour depend on the variety of wheat as well as maximum % age of bran removal before the milling process. White bread flour is more refined because the maximum bran is separated from the rest of the grain and consider more safer than Brown bread flour. In whole wheat flour production the whole grain is used. Brown flour has higher extraction rate than white bread flour since it contains more bran content thus giving the flour a darker color and a stronger flavor and odor (Anon. 2004a; Anon. 2005e). In most of the milling process coarse bran is removed at 1st break stage and packed separately as animal feed
n
3444
Sample Number
448
Positive %
13
Staph.aureus
3126 4360
1 47
0 1
Salmonella b
Basic PRP
Following Pre-requisite programs should be in place before HACCP implementation : Good Manufacturing Practices (GMP), Good Agricultural Practices (GAP), Good Hygiene Practices (GHP) i.e cleaning and sanitation Good Laboratory Practices (GLP) Pest Control Control of operation: temperature and time is critical to the safety of the food Storage, packaging, distribution and transportation Maintenance, Training If HACCP is implemented before the pre-requisite programs are in place, it could lead to a complicated HACCP system with too much critical control points (Mitchell 1992). Of all these pre-requisite programs the Good Manufacturing Practices (GMP) and Good Hygiene Practices (GHP) are the most important and should be documented, monitored, confirmed and reviewed frequently. If these practices are well-developed and frequent auditing shows consistency, the food safety plan (in this case the HACCP plan), is noticeably simplified.
Product description
1. Product name 2. Important product characteristics 3. How the product is to be used 4. Packaging (I,2,5kg) 5. Shelf-life 6. Where the product will be sold 7. Labeling instructions 8. Special distribution control Wheat flour Total microbial count 50000/g end product Normally fortified Sealed polythene /Paper bags 6 month at retail shelf Retail, commercial bakeries & food service. Shows product storage & safety. No physical damage, excess humidity or temperature
Type
Control Measures
Preliminary cleaning, aspiration, removal of un millable material, intermediate cleaning, cleaning house: aspirator ,separator, combinator, combi-cleaners, de-stoner,carter disk, treur cylinder, scourer, magnets, metal detectors, pest control program
Physical
Chemical
Biological
Aspergillus spp. Penicillium spp (can produce mycotoxin as by product) Fusarium graminearum
(produce vomitoxin / deoxynivalenol / DON)
control temperature and moisture condition, temperature should not exceed 25 C, moisture should not exceed grading specifications (13 -14%) %), aw should be <0.90 to prevent Fusarium from growing and producing DON/NIV
(Hope and Magan)
Control Measures
Control measures to minimize the presence of moulds and mycotoxins should be implemented at the grain handling, transportation, storage and milling stages. No report comparing overall microbial load in wheat and its relationship to quality parameters available. This limits our ability to provide solid technical evidence of acceptable limits of bacteria, yeasts and moulds. For this an additional data is required that can help to (I ) establish defines normal microbial loads in wheat shipments, (ii) verify authenticity/reliability of microbial counts (iii) identify factors contributing to high counts (iv) evaluate the relative contribution of wheat to the health hazard risk associated with baked products.
Flour as a Carrier
In certain specialized circumstances, customers may want to use flour in an application that has no kill step, such as baking. Such circumstances include the use of flour as a carrier for nutraceuticals, pharmaceuticals, spices, or flavors; or as a bulking/caloric agent in dried mixes, including geriatric and infant foods. In these cases, the flour must be pretreated to eliminate the possibility of pathogen contamination. If such a treatment is not practical, flour should not be used for such specialized purposes.
CCP: At Receiving
The hazards associated with the CCP namely receiving are physical , chemical and biological In order to verify whether the above mentioned step in the process is a critical control point, Yes Whether control measures exist at this specific stage. The answer to this question is yes The COA,CAC, physical and chemical analysis report and certificate of Origin from the supplier and preloading and unloading inspection reports, Secondly the question is raised whether that step is specifically enough to eliminate or reduce the occurrence of the hazard to an acceptable level. Yes Therefore the grain receiving could be regarded as a CCP.
CCP: At Conditioning
The hazards associated with the CCP namely conditioning stage before milling are mud, moisture contents and micro flora In order to verify whether the above mentioned step in the process is a critical control point, Yes Whether control measures exist at this specific stage. The answer to this question is yes cleaned water addition, specific moisture content, controlled temperature and time, scourer and aspirator, peeler (In GCC) and turbulizer system are in place. The question is raised whether these operational steps are specifically designed to eliminate or reduce the occurrence of the hazard to an acceptable level. Yes Most of the mud and dirt will be removed during this process
Milling Process CCP Rebolt sifter, metal detector and impactor before packaging
The physical hazards associated with the CCP namely the rebolt sifter, metal detector and impactor before packaging, are insects, insect eggs and metal pieces. In order to verify whether the above mentioned step in the process is a critical control point, Yes Whether control measures exist at this specific stage. The answer to this question is yes because a rebolt sifter, metal detector and impactor system are in place. Secondly the question is raised whether that step is specifically designed to eliminate or reduce the occurrence of the hazard to an acceptable level. Yes Any living forms of insects will be removed by the rebolt sifter that might have escaped the other methods of detection. The impactor after a rebolt sifter assures that any form of insect that passed through a damaged rebolt sifter sieve, will be destroyed and the metal detector will give an indication of the presence of metal. Therefore the rebolt sifter, metal detector and impactor systems could be regarded as a CCP.
Critical limits
No sign of chemical, biological or microbial or physical damaged product
Corrective Actions
COA, COC, Health and pytocenitary , and inspection certificate, Turbulizer, peeler, scourer and aspirator in order to remove skin ,dust and mud to reduce bacterial count metal detector and impactor before packaging. Stop production. Replace sieves. Fumigation. Sterilator.
Verification
Records
Wheat Receiving
Wheat Conditioning
Physical and microbiologial Physical Hazards infestation of insects and insect eggs, metallic pieces
Analysis reports
The End
References
Bas, M., Ersun, A.S. and Kivanc, G. (2004). Implementation of HACCP and prerequisite programs in food businesses in Turkey. Food Control, In Press. Billy, T.J. (2002). HACCP a work in progress. Food Control, 13 (6-7), 359-362. DeWaal, C.S. (2003). Safe food from a consumer perspective. Food Control, 14 (2), 75-79. Heggum, C. (2001). Trends in hygiene management the dairy sector example. Food Control, 12 (4), 241-246. Mead, P.S., Slutsker, L., Dietz, V., McCaig, L.F., Bresee, J.S., Shapiro, C., Griffin, P.M.,and Tauxe, R.F. (1999). Food-related illness and death in the United States. Emerg Infec Dis, 5 (5), 607-625. Mortimore, S. and Wallace, C. (1995). HACCP: A practical approach. London: Chapman and Hall. National Advisory Committee on Microbiological Criteria for foods. (1998). Hazard analysis and critical control point principles and application guidelines. J Food Prot, 61(6),762-775. Sperber, W.H. (2005). HACCP does not work from farm to table. Food Control, 16 (6), 511-514. Sun, Y.M. and Ockerman, H.W. (2005). A review of the needs and current applications of hazard analysis and critical control point (HACCP) system in foodservice areas. Food Control, 16 (4), 325-332. Todd, E.C.D. (1989). Preliminary estimates of costs of food-borne disease in the United States. J Food Prot, 52, 595-601. Trujillo, A.J. (2000). Cereal food industry: Are you HACCP ready? Cereal Foods World, 45 (4), 157-160. Untermann, F. (1999). Food safety management and misinterpretation of HACCP. Food Control, 10 (3), 161-167. Uys, R. (2000). The benefits of the hazard analysis critical control point (HACCP) system in the fishing industry. M.Sc Thesis. Youn, S.M.S. and Sneed, J. (2003). Implementation of HACCP and prerequisite programs in school foodservice. J Am Diet Assoc, 103 (1), 55-60. Wallace, C. and Williams, T. (2001). Pre-requisites: a help or a hindrance to HACCP? Food Control, 12 (4), 235-240. Walker, E., Pritchard, C. and Forsythe, S. (2003). Hazard analysis critical control point and prerequisite programm implementation in small and medium size food businesses. Food Control, 14 (3), 169-174. (Slide#39)
REFERENCES
1. Richter, K. S., E. Dorneanu, K. M. Eskridge, and C. S. Rao. 1993.Microbiological quality of flours. Cereal Foods World 38 (5): 367-369. 2. Cicognani, G., C. Pedretti, and A. Cerrato. 1975. Microbiological characteristics of wheat flours. Industrie Alimentari 14: 60-64. 3. Pozo, E. del., V. Leyva, O. Perez, M. delos Reyes, and Y. Ferrer. 2000. Detection of Salmonella in feed for laying hens. Alimentaria 37 (316): 93-97 4. Eiroa, M. N. U., L. Freitas, L Ferreira, and P., Vitti. 1975. Microbiological characterization of flours and starches. ColetaneaInst. De Tecnol.de Alimentos 6 (2): 459-473. 5. Sperber, W. H. 2001. Personal communication. 6. Kehl, B. and W. Bostel. 1999. Examination of the current sanitary condition in milled wheat products of the pasta industry. Getreide Mehl und Brot 53 (4): 242248.
References
1. Richard-Molard, D. 1994. The microbiology of cereals and flours. Chapter 2 (pp. 143-154) in: Primary Cereal Processing; A Comprehensive Sourcebook. B. Godon and C. Willm (Eds.), VCH Publ. Inc., New York, NY. 2. Fung, D.Y.C. 1995. Microbiological considerations in freezing and refrigeration of bakery foods. Chapter 6 (pp. 119-133) in: Frozen and Refrigerated Doughs and Batters. K. Kulp, K. Lorenz and J. Brummer (Eds.), American Association of Cereal Chemists, St. Paul, MN. 3. Kotsianis, I.S., V. Giannou and C. Tzia. 2002. Production and packaging of bakery products using MAP technology. Trends Food Sci. Technol. 13:319-324. 4. Gelinas, P. 2003. Flour know-how? Bakers Journal 63(7): 14-15, 66. 5. Sperber, W.H. 2003. Microbiology of milled cereal grains: Issues in customer specifications. Technical Bulletin of the IAOM. 3(6): 79297931.
References
6. Manthey, F.A., C.E. Wolf-Hall, S. Yalla, C. Vijayakumar and D. Carlson 2004. Microbial loads, mycotoxins and quality of durum wheat from the 2001 harvest of the Northern Plains Region, USA. J Food Protection 67(4): 772-780. 7. Dale, H. 2003. Microbial threats in the bakery. International Food Hygiene 14(1): 9-10. 8. Smith, J.P., D.P. Daifas, W. El-Khoury and J. Koukoutsis. 2002. Foodborne illnesses associated with bakery products. Technical Bulletin of the American Institute of Baking. 24(4) 1-11. 9. Smith, J.P., D. Phillips Daifas, W. El-Khoury and J.W. Austin. 2003. Microbial safety of bakery products. Chapter 1 (pp. 3-33) in: The Microbial Safety of Minimally Processed Foods, J.S. Novak, G.M. Sapers and V.K. Juneja (Eds.), CRC Press, Boca Raton, FL. 10. Canadian Food Inspection Agency web site. Food Recalls. Last accessed 30 January 2004 at: http://www.inspection.gc.ca/englush/corpaffr/recarapp/recaltoce.shtml Dr. Mingwei Wang ,Technical Specialist, Baking Technology ,CIGI,Canada Gordon R. Carson ,Director, Cereal Technology ,November 27, 2005