الفهرس 
HACCP system food hygiene and food safetyOnly 14 pages are availabe for public view
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Abstract
The assurance of safe production and the supply of adequately safe and healthy food products appear to be the main aims of the food industry. These aims can be achieved by adopting a systematic and organizational structure, controlling activities, procedures and resources according to the standards which constitute the basis for total quality systems, including ISO 9000 series and the Hazard Analysis Critical Control Point (HACCP).
Food safety is related to quality and is one of the main characteristics that a product of this sector must have, and various systems and standards have been developed to support this, one of these being the Hazard Analysis Critical Control Points (HACCPs).This approach is aimed at identifying potential food safety hazards in order to apply key action that can reduce or eliminate the risk of the hazards being realized.
The diversity of bakery products make them attractive for customer, but also make them hard to organise the development and implementation of HACCP concepts. So, the modern approach of HACCP based on the use of experts applying a series of searching questions concerning potential hazards and their control, in a systematic and formalised manner to all stage in food operation. Bakery products can be classed according to their ingredients, chemical profile or production method. Each of these parameters provides information on the inherent microbiological risks potentially associated with a product.
Therefore, the main objectives of this study were to
1- Assess the microbiological quality and physicochemical properties of some bakery products (i.e. plain &filled biscuit and cake samples) collected from local markets.
2- Identify the hazards and CCPs of the collected bakery products.
3- Detect the presence of some pathogenic bacteria (S.aureus, Salmonella spp. and E. coli) in cream samples separated from the collected filled – bakery products.
4- Improve the safety and quality of prepared filling cream by applying some control measures (i.e., cooling, pasteurization, addition of natural preservatives, and reduction of pH).
5- Assist and implementation of HACCPs concepts and principles during preparation of filling cream.
The obtained results can be summarized as follows:
5.1. Hazard analysis of some bakery products collected from local market
5.1.1. The pH of plain and filled-biscuit samples was ranged between 6.11-8.45 and 6.44-8.60 respectively, while the moisture content was ranged between 3.95-6.79% and 6.87-8.65% for the aforementioned samples. Plain and filled-cake samples characterized by higher moisture content (16.97-29.66%) and lower pH (4.48-7.07) than biscuit samples.
5.1.2. All tested plain biscuit samples contained low count of total aerobic bacterial, spore forming bacteria and yeasts & molds counts and were free of pathogenic bacteria (S.aureus, Salmonella spp. and E coli). On the other hand, the microbial load of collected filling biscuit products were higher than that of plain biscuit samples. S.aureus was detected within a range of 2.00 to 2.47 log cfu/g of the tested filling biscuit. Also, three filling biscuit samples were contaminated with E coli with value of 2.00 log cfu/g.
5.1.3. The microbial load of different collected filling – cake sample were higher than those of the plain cake products. Although S.aureus was not detected at detection limit ˂101 cfu/g of plain cake samples, it was detected in all filling cake samples in counts ranged from 2.30 to 2.60 log cfu/g. Also, Salmonella spp. and E coli were detected at least in three samples of ten tested filling cake products
5.1.4. The survey showed that the microbiological statuses of plain biscuit and cake samples were satisfactory according to the microbiological guideline for ready-to-eat foods. Also, all filled collected samples contained higher microbial load than plain samples and this could be due to the presence of sensitive materials in the components of filling cream. Different collected filled-samples showed unacceptable levels of coagulase-positive staphylococci (2.3-2.6 log cfu/g) and E. coli & Salmonella spp. were detected in 30-40% of the tested filled samples.
5.1.5. The microbiological analysis of the cream separated from the collected filled-bakery products showed that all cream samples contained S.aureus with counts ranged from 2.30 to 2.69 log cfu/g. Also, cream separated from three filled-biscuit and four filled-cake samples had a potentially hazardous level of E. coli (2.00 log cfu/g). Salmonella spp. was detected in 3 and 5 cream samples separated from 10 tested biscuit and cake products respectively.
5.2. Application of HACCP system in production of filling cream.
According to the aforementioned results, it could be concluded that filling cream and filling step in manufacturing of filled-bakery products could be a major source of pathogenic bacteria in the final product. Therefore, implementation of HACCP principles in production of filling cream was applied to improve the safety of filled-bakery products and the obtained results can be summarized as follows:
5.2.1. Microbiological analysis showed that milk powder was the main potentially hazard raw materials used in preparing filling cream especially pathogenic bacteria.
5.2.2. Receiving raw materials and whipping step are considered as a CCP during manufacturing of filling cream. Also, filling step recorded as a CCP during processing of filling bakery products. Filling cream was identified as risk group of IV.
5.2.3. For improving the safety of filling cream, microbiological control measures including cooling, pasteurization, addition of natural preservatives (lemongrass oil, herbs of cinnamon, clove, and anise and reduction of pH using fruit pulps of strawberry, apricots, and apple) were applied. A significant (p≤0.05) increase in different microbial count was observed during storage of filling cream at 4ºC for 10 days. Pasteurization process at 80ºC for 10 min significantly reduced count of total bacteria, yeasts & molds, S. aureus, and E. coli to ˂1 log cfu/g, while spore forming bacteria was only decreased to 2.18 log cfu/g. However, Salmonella spp. was not detected in any 5 replicates of the pasteurized cream samples. Addition of lemongrass essential oil to filling cream at levels 2 and 3 µl/g has antimicrobial activity against a range of microorganisms’ particularly pathogenic bacteria during 10 days of cold storage. The pH value of cream with 20, 18, and 20% of strawberry, apricots, and apple pulps respectively (which achieved good sensory attribute in filled sponge cake) were ranged between 4.53-4.68, while it was 6.58 for control. Results showed that cream products with fruit pulps were less suitable for microbial growth than ”neutral” real cream. No significant changes were observed in the counts of S. aureus, Salmonella spp and E. coli during cold storage of fruit pulp – cream for 10 days. Addition of 3.0, 2.5 and 3.0 % of cinnamon, clove and anise herbs significantly improved the safety of filling cream especially pathogenic criteria as E. coli and S. aureus which were not detected at detection limit ˂ 1 log cfu/g. While, Salmonella spp. was not detected in any 5 tested samples.
In conclusion different applied control measures led to reduce microbiological criteria of filling cream to acceptable levels especially pathogenic bacteria. However, pasteurization and reduction of pH (addition of fruit pulp) are still the most important measure to prevent microbiological growth.
5.2.4. Other HACCP principles critical limits, monitoring, corrective actions, verification, and records were established. Implementing the HACCP system during preparing filling cream can effectively ensure safety of this products and other food products contained filling cream especially bakeries.