FORTIFIED DATE-BARS (GAZA-IRAQ specifications)

Transcription

1 Technical Specifications for the manufacture of: FORTIFIED DATE-BARS (GAZA-IRAQ specifications) Specification reference No.: Date-bars Date of issue: September 2009 Version: 1.0 Updated: 16 September INTRODUCTION 1.1 Product purpose Date-bars are provided as a supplement to the diet of school children. 1.2 Product type Date-bars are biscuits filled with date paste which is fortified with a premix of minerals and vitamins. Date-bars provide a supplement of energy, proteins, fats and micronutrients to the daily food ration. Date-bars are culturally well-accepted by populations living in Middle East, and belong to the category of ready-to-eat food. 1.3 Standards and recommendations Date-bars shall be manufactured in accordance with: Recommended International Code of Practice: General Principles of Food Hygiene CAC/RCP Rev Amended (1999) including Annex Hazard Analysis and Critical Control Point (HACCP) System and Guidelines for its application 1 / 8

2 2. RAW MATERIALS 2.1 Main ingredients Date-bars shall be manufactured from fresh raw materials of good quality, free from foreign materials, substances hazardous to health, excessive moisture, insect damage and fungal contamination and shall comply with all relevant food laws and standards. Date-bars shall be manufactured from high quality wheat flour, dried skimmed milk, dates and sugar and other ingredients according to the Recommended International Code of Practice General Principles of Food Hygiene CAD/RCP , Rev.4, Biscuit Wheat flour should conform to Codex STAN Shortening: the only shortening agent allowed is palm oil as per codex STAN Sugar should conform to Codex STAN Skimmed milk powder should conform to Codex STAN It shall be accompanied by a melamine-free certificate. - Maximum level aflatoxin M1: < 0.5 mcg/kg milk (recommended methods ISO 14501/IDF 171: or ISO 14674/IDF 190: ). Additives - Lecithin shall be in proportion as specified in the Codex STAN Raising (SODA) agent as specified in the codex STAN , the maximal value is determined by the GMP principles. - Shortening: the only shortening agent allowed is palm oil as per codex STAN Date paste Date should conform to Codex STAN Sugar should conform to Codex STAN Shortening: the only shortening agent allowed is palm oil as per codex STAN Milk and milk powder: determination of aflatoxin M1 content, clean up by immunoaffinity chromatography and determination by HPLC. 2 Milk and milk powder: determination of aflatoxin M1 content, clean up by immunoaffinity chromatography and determination by Thin Layer Chromatography. 2 / 8

3 The ingredients must be stored under dry, ventilated and hygienic conditions. Only safe insecticides (i.e. phosphine gas) may be used for storage. Fumigation SOP ( 2.2 Vitamins and minerals Minerals and vitamins they shall conform to Codex Standard CAC/GL Advisory list of nutrient compounds for use in foods for special dietary uses intended for infant and young children. The addition of the premix shall conform to Codex Standard CAC/GL General principles for the addition of essential nutrients to foods. Complete premixes must be purchased from a WFP approved suppliers: DSM, Fortitech, Nicholas Piramal and Hexagon Nutrition or their authorized dealer (addresses of suppliers are in annex). Micronutrient premixes must be delivered to the processor of Date-bars with a complete Certificate of Analysis as well as with a Proof of purchase of premixes. The two documents must be presented with other documents for payment. Premixes must be stored in a dry, cool and clean place where the temperature does not exceed 25 o C. 3 / 8

4 3. PROCESSING 3.1 Formula Date-bars are filled biscuits in which the biscuit represents 70% of the bar and the filling with date paste represents the other 30%. The formula is proposed in table 1. Table 1: Formula of Date- bars Part 1: Biscuit (dough) Percentage 1 Wheat flour Fat (palm oil) Raising agent Water Milk Sugar (sacharose/fructose/glucose) 7.00 Total dough Part 2: Date paste (filling) 1 Fat (palm oil) Sugar (sacharose/fructose/glucose) Date Premix 0.25 Total filling Total (p.1+ p.2) Mixing with premix of minerals and vitamins Dosage: premix quantity to add is 835g of premix /100 kg of total filling which represents 30% of the finished product. Mode of mixing: Premix should be added in the date paste filling, as follow: To dilute the premix homogeneously in the added sugar. To mix the added sugar + premix with the shortening in the Z-shape blender. To add 1/3rd of the date paste in the Z-shape blender To mix for 5 10 minutes To add the remaining of date paste in the Z-shape blender To mix for an additional minutes. Date-bars manufacturers should send their calculations to the Quality control Unit in Rome for purpose of verification. 3.3 Food safety and risk assessment at manufacturing premises For compliance with Codex standards the processor must be able to demonstrate by principle and practice the adoption, implementation and recording of: Good Manufacturing Practice Hazard Analysis Critical Control Point program 4 / 8

5 In this context an appointed WFP Inspector / Quality Surveyor is entitled to visit the factory without prior notice during any period when WFP product is being manufactured to check that the GMP and HACCP systems are in place. The Inspector / Quality Surveyor may request to see: Records (i.e. names of people in charge of the process and quality control, temperatures of the process, mixing times / quantity, cleaning schedules, etc). Procedures (e.g. cleaning, personnel hygiene, HACCP, sampling and analysis). Instructions (e.g. process instructions, cleaning instructions). The quality manual for the process or factory. The manufacturer must be registered under national food law as a processor of foods for human consumption. 5 / 8

6 4. PRODUCT SPECIFICATIONS 4.1 Moisture content 12% maximum 4.2 Nutritional value: it shall contain the following nutritional value per 100 g dry matter: Energy 430 kcal Protein 8.0 % (N x 6.25) Fat 12.0 % Added sugar 10.0 % 4.3 Micronutrient Date-bars must be fortified with a premix in order to provide the following micro nutrient supplement per 100g dry matter of finished product: Table 2: Micronutrient rate and chemical form Micronutrients Per 100g Chemical form Vitamins Vitamin A IU DRY V ITAMIN A PALMITATE S/N Vitamin D 114 IU DRY VITAMIN D3 100 SD/S Tocopherol Equivalent (Vitamin mg DRY VITAMIN E 50% CWS/S E) 4.0 Vitamin K mg Dry Vitamin K1 5% SD Thiamine (Vitamin B1) 0.51 mg THIAMINE MONONITRATE Riboflavin (Vitamin B2) 0.51 mg B2 UNIVERSAL FINE POWDER Pyridoxine (Vitamin B6) 0.57 mg PYRIDOXINE HYDROCHLORIDE Vitamin C 17.0 mg ASCORBIC ACID Folic Acid (Vitamin B9) 0.17 mg Folic Acid 10% on Potato Malt Niacinamide 6.8 mg NIACINAMIDE Vitamin B µg Vitamin B12 0.1% WS N Minerals Copper 0.34 mg Copper Gluconate Iron 7.10 mg Ferric Pyrophosphate Zinc 3.18 mg Zinc Oxide The permitted variation in premix content is -10 to +15% for added vitamins and +/- 10% for added minerals. Note: Variable levels of micronutrients naturally present in raw materials lead to variable amount of micronutrients in finished product. 4.4 Microbiology not to exceed the following levels of microbiological contamination in the finished product: 6 / 8

7 Table 3: Limit of microorganisms in Date-bars Microorganisms Mesophyllic aerobic bacteria Coliforms Salmonella Escherichia Coli Staphylococcus Yeasts and moulds Maximum levels 10,000 cfu per g < 10 cfu per g 0 per 25g < 3 cfu per g < 3 cfu per g 100 per g 4.5 Additional Requirements Date-bars shall meet the following additional requirements: Taste: it shall have a pleasant smell and palatable taste which children will like and enjoy. Shelf life: it shall retain above qualities for at least six months from date of manufacture when stored dry at ambient temperatures prevalent in the country of destination Safety: it shall be free from objectionable matter; not contain any substances originating from micro-organisms or any other poisonous or deleterious substances such as anti-nutritional factors, heavy metals or pesticide residues, in amounts which may represent a hazard to health: - Toxins permitted level of aflatoxin M1: - Heavy Metals Arsenic (As) Cadmium (Cd) Lead (Pb) Mercury (Hg) - Pesticide residues Carbamate Organochlorine Organophosphorus Pyrethroid < 0.5 ppb < 0.10 ppm < 0.10 ppm < 0.02 ppm < 0.20 ppm < 10 ppb < 10 ppb < 10 ppb < 10 ppb - Melamine max 2.5 mg/kg Other requirements Free from radioactivity. Free from Genetically Modified Organisms (if required by the contract). 7 / 8

8 5. PACKAGING The Date-bars shall be individually packed in containers which will ensure the hygiene and the quality of the product. Any packaging material shall be made of safe substances, suitable for Date-bars conservation, ideally a laminated plastic foil. For long preservation an aluminium layer will be required. 6. MARKING On packs Name of the product: Date-bars. Net content: 80 g. Nutrition information. - Energy (in kcal/100g dry matter). - Protein (in g/100g dry matter). - Fat (in g/100g dry matter). - Enriched with 11 vitamins and 3 minerals. Best before date. Additional marking as per contractual agreement. On cartons Name of the product: Date-bars. Net content:...packs x 80g Name and address of the supplier (including country of origin). Batch number (or SI). Best before date. Additional marking as per contractual agreement. 7. STORING Date-bars must be stored under dry, ventilated and hygienic conditions. 8 / 8