Storage and dispatch - GMP

No subsequent contamination with patulin is likely.

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Tasks 11: Establish verification procedures

The HACCP plan will be audited quarterly, and amended as necessary.

Tasks 12: Establish documentation and record keeping

The HACCP Plan will be fully documented, and appropriate records kept at each CCP.

References

Acar, J., Gokman, V., Taydas, E. E. (1998). ‘The effect of processing technology on the patulin content of juice during commercial apple juice concentrate production’. Zeitschrift fur Lebensmittel-Untersuchung und-Forschung A-Food Research and Technology 207, 328-331.

Anon (1999). ‘Guidance on the control of patulin in directly pressed apple juice.’ Published by the UK Ministry of Agriculture, Fisheries and Food, Ergon House, 17, Smith Square, London SW1P 3JR.

Canas, P., Aranda, M. (1996). ‘Decontamination and inhibition of patulin-induced cytotoxicity.’

Environmental Toxicology & Water Quality 11, 249-253.

Sydenham, E. W., Vismer, H. F., Marasas, W. F. O., Brown, N., Schlechter, M., Vanderwesthuizen, L., Rheeder, J. P. (1995). ‘Reduction of patulin in apple juice samples – influence of initial processing.’ Food Control 6, 195-200.

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Example 6: Pistachio nuts in West Asia

Introduction

Pistachio nuts in this Region are grown commercially in Afghanistan, Iran, Iraq and Turkey. In the first three countries the nuts are usually dehulled very soon after harvest and the nuts in shell are then stored and processed (fast lane). In Turkey, however, the nuts are stored in-hull, sometimes for many months, or even for years (slow lane). Early de-hulling has the advantage of avoiding staining of the shell, but has the disadvantage of exposing the split nuts at an early stage to Aspergillus flavus and A. parasiticus spores which have the potential to produce aflatoxin.

The pistachio nut is the fruit stone of Pistacia vera. Each fruit has a single stone which consists of a kernel covered by a testa and enclosed in a shell. The shell itself is enclosed in a protective hull.

One month or more before maturity the shell usually partially splits within the hull. The hull should remain intact, but sometimes it also splits naturally prior to harvest and these ‘early splits’ and

‘growth-splits’ are particularly susceptible to aflatoxin contamination. Early splitting allows invasion by insects, particularly the navel orangeworm [Amyelios transitella (Walker)] and insect- damaged nuts are associated with a high risk of aflatoxin contamination.

Different varieties of pistachio trees are grown in the Region. In Iran, Iraq and Afghanistan varieties are grown which tend to have large nuts with hulls which are relatively prone to early splitting, although climatic factors also have a bearing on this. In Turkey the pistachio varieties tend to yield smaller nuts with greener kernels and these have hulls which are not very susceptible to early splitting.

De-hulling can either be carried out using a wet-process or a dry process. The former is used by large-scale factories and some medium-scale factories, whereas the latter process is carried out mostly in cottage industries.

Collecting a representative sample of pistachio nuts for aflatoxin testing is particularly difficult because it has been established that the incidence of significantly contaminated nuts is usually very low, in the order of 1 nut in 10,000 to 1 nut in 30,000 (or more). This means that even a 30 kg sample, as recommended by the European Union, may only contain a single contaminated nut.

However, pistachio nuts can contain very high levels of aflatoxin, up to 1,000,000 ng, so a single contaminated nut could give a level of 33 µg/kg (ppb) in a 30 kg sample.

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The nuts are exported in a number of forms including: whole raw nuts for further processing;

roasted and salted nuts with or without red staining; and kernels for the food manufacturing industry.

This example is based on a blend of two studies that covered the pistachio commodity system across the whole Region. The wet process of de-hulling followed by segregation by flotation is illustrated here. Although this ‘re-wetting’ introduces a potential risk of further aflatoxin contamination, this can be eliminated by the correct use of efficient mechanical driers. If such driers are NOT available, then a dry process should be used.

Pre-requisite programmes that must be in place include: GAP, GSP, GMP, and the more specific

‘Codex Recommended International Code of Hygienic Practice for Tree Nuts (CAC/ RCP 6- 1972) (FAO/WHO,1994b)’. The latter covers basic hygienic requirements for orchard, farm processing, and commercial processing.

Task 1 - The HACCP team

An appropriate HACCP team will include: HACCP specialist, factory manager, factory quality assurance manager, mycotoxicologist, mycologist, edible nut specialist, procurement agency manager, laboratory manager, socio-economist, and representatives of the Department of Agriculture and of the private sector farming, domestic trading and export sectors.

Tasks 2 and 3 - Product description and intended use.

The product description and intended use is given in Table 13.

Table 13. Product description and intended use of pistachio nuts Name of Product Confectionery Pistachio Nuts

Description Pistachio nuts, partially split, roasted and salted Customer specification Ready-split, white or red-stained shells. No obviously

mouldy nuts and no rancid nuts. Aflatoxin limit, e.g. 2 µg/kg B1, 4 µg/kg total for EU.

Conditions of storage Ambient temperature, but < or =10°C preferred for (finished product) long-term storage.

Shelf Life 1 year

Intended use Confectionery snack food

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Packaging Plastic-foil laminate, vacuum sealed or over nitrogen Target Consumer European and US

Target level is < or = 2 µg/kg aflatoxin B₁ for export to the EU and < or = 20 µg/kg total aflatoxin for export to the US.

Tasks 4 and 5: The Commodity Flow Diagram (CFD), Verified

The CFD was established and verified, as in Figure 13.

Fig. 13. HACCP Process Flow-diagram: Pistaccio Nuts, roasted - West Asia

Step Classification

1) Farm IPSM

Pre-harvest Farm

2) Harvesting CCP1