APPLICATION OF THE HACCP SYSTEM

TO THE PREPARATION OF
CHOCOLATE BAR
IMPLEMENTATION OF THE HACCP SYSTEM IN THE PRODUCTION OF CHOCOLATE
BAR

LADY BERNAL
DIEGO MOLINA
CARLOS CASTELAR

Subject:

FOOD SAFETY MANAGEMENT SYSTEMS

IX SEMESTER

Teacher:

Q.F. OSCAR DE CASTRO ARZUZA

ATLANTIC UNIVERSITY

CHEMISTRY AND PHARMACY

BARRANQUILLA

2019-1

PHARMACY PROGRAM
 INTRODUCTION

The Colombian Technical Standard ISO 22000:2005 is an international standard suitable

for any company in the food chain, including interrelated organizations such as producers
of equipment, packaging material, cleaning agents, additives and ingredients. Therefore, it
must meet certain requirements regarding the food safety management system to ensure
food safety throughout the entire food chain, allowing quality and health for the consumer.

GOALS
● Simulate the production of a food product, applying the HACCP system, to achieve
safety.

● Establish an alternative to make a chocolate bar that guarantees its safety.

IMPLEMENTATION OF THE HACCP SYSTEM IN THE PRODUCTION OF APPLE
NECTAR JUICE

1. HACCP TEAM MEMBERS

The HACCP team is a multidisciplinary team that not only includes pharmaceutical
chemists but also: engineers, biochemists, microbiologists, external specialists with
knowledge of the physical, chemical and biological hazards associated with the product.
The HACCP team is made up of:

⮚ Manager or administrative head: Lady Bernal Contreras

Functions: Person responsible for food safety and security and the implementation of the
HACCP system

⮚ Head of Quality Control: Diego Molina

Functions: person in charge of product quality, reporting any failure that occurs, monitoring
that the production processes comply with the quality specification.

⮚ Production Manager: Carlos Castellar

Functions: person in charge of all production processes in the company, verify the
conditions of raw materials, materials and equipment, direct personnel in production.

⮚ Head of sales or marketing: Charly Barreto Novoa

Person in charge of everything related to the transfer and distribution of the final product to
customers, registering complaints or claims, product advertising.

⮚ Operators: Tatiana Rodríguez

Provide practical knowledge in the different operations in the manufacturing of the product.

2. PRODUCT CHARACTERIZATION
Name and description of the product.
Chocolate is a multicomponent system made up of a suspension of sugar, cocoa particles
and milk (depending on the type), covered by phospholipids (fats) in a continuous phase of
cocoa butter with a percentage of 65 – 75% solids. 1
Chocolate is made from cocoa beans that are conveniently fermented in the place of
origin, dried and exported to the country where it will be made. The seeds are roasted,
hulled, and the germ is removed to leave the cocoa bean clean. Under these conditions,
the beans are ground until obtaining a paste called cocoa mass or liquor. This dough is
mixed with sugar and cocoa butter and undergoes a refining process and what is called
“concheo” in confectionery. An appropriate seasoning (usually vanilla) is then added, and
the product is ready for use 1 . Cocoa butter is obtained by extracting the fat from the
cocoa mass; The residue that remains is used as cocoa powder. The conching process
involves stirring the mixture while it is heating, so that all of the dough remains exposed to
the air. This operation allows a notable improvement in flavor. In sweets made with milk
and chocolate, milk is added to the mixture, appropriately before subjecting it to the
refining process 1 .
The main categories of chocolate are: dark, milk and white chocolate, which differ in cocoa
liquor, milk fat and cocoa butter content. The result is varied proportions of carbohydrates,
fat and protein. Regarding triglycerides in chocolate, saturated stearic (35%) and palmitic
(26%) fatty acids and monosaturated oleic acids (35%) stand out (Table 6). Chocolates
are solid at room temperature (20-25°C) and melt at body temperature (37°C) during
consumption, giving a smooth suspension of solid particles in cocoa butter and milk fat 1 .

Table 1. Typical composition of fatty acids in cocoa butter.

Fatty acids Formulation % Average

Mysteric Acid C14:0 0,1 %
Palmitic acid C16:0 26,0 %
Palmitoleic Acid C16:1 0,3 %
Stearic Acid C18:0 35,0 %
Oleic acid C18:1 35,0 %
Linoleic acid C18:2 3,0 %
Linolenic Acid C18:3 0,2 %
Arachidic Acid C20:0 1,0 %
Behenic Acid C22:0 0,2 %

Source taken: Simón Bolívar University. 2011[1]

2.1 INGREDIENTS:
Cocoa:
The cocoa seed comes from the cocoa tree called Theobroma cacao L. The cocoa seed
can be extracted from the shells that contain between 30 – 40 seeds each, covered with a
white pulp rich in sugars. These seeds consist of a shell that covers two cotyledons and a
germ that is the embryo of the plant. The cotyledons store food for the embryo, so more
than half of their weight is cocoa butter. In order to process the seed, it must go through a
fermentation process, creating a series of chemical and microbial changes, generating
sugars and acids that give the characteristic flavor to chocolate. This process normally
takes 5 to 6 days. After fermentation, the seed goes through a toasted drying process,
where the seed is left with a little more than 6% humidity to avoid its fragility and with a
darker characteristic of chocolate. The roasting process also allows the degradation of
amino acids and the volatilization of acids that contribute to the acidity and bitterness of
the product. Finally, the seed can be ground to generate cocoa liquor and cocoa butter.
• Refined white sugar: Refined white sucrose, or as we will call it from now on refined
white sugar, is a carbohydrate and we could break it down as a polysaccharide (it has one
fructose molecule and one glucose molecule).
Sugar
Sugar or sucrose (a disaccharide formed by two monosaccharides called glucose and
fructose) is the product of sugar cane or beets. Due to its high purity, it can generate
crystals with sizes ranging from 0.005 mm to 1 mm. In most chocolates, a fine size ranging
from 0.6 mm to 0.001 mm is used [50]. The effect that sugar generates on chocolate will
be mainly at the flavor level. However, a change in sugar size also modifies the viscosity of
chocolate [44]. The amount of sugar used by manufacturers is approximately 50%.
Glucose syrup, invert sugar, fructose or artificial sweeteners are also used.
• Citric acid, as an acidity regulator: Citric acid is one of the additives most used by the
food industry. It is obtained by fermentation of different raw materials, especially sugar
cane molasses. Citric acid is an organic tricarboxylic acid that is present in most fruits,
especially citrus fruits such as lemon and orange. It is a good preservative and natural
antioxidant that is added industrially in the packaging of many foods such as canned
vegetables.
• Drinking water : The water used in the manufacture of fruit juices must meet the
physical, chemical and microbiological conditions indicated in the technical-sanitary
regulations for the supply and quality control of drinking water for public consumption.

2.2 NUTRITIONAL VALUE OF CHOCOLATE

Table 1 nutritional value

2.3 PHYSICOCHEMICAL AND ORGANOLEPTIC CHARACTERISTICS

2.3.1 Chemical Composition of Chocolate.

Table 3. Chemical composition of unsweetened and sugared dark chocolate (per

100g edible portion).
Components dark chocolate dark chocolate Unit
without sugar with sugar
Proximal
alcohol (ethanol) 0 0 g
Total energy 543 532 Kcal
fat, total (total lipids) 29.2 30 g
protein, total 4.7 2 g
water (humidity) 1.3 5 g
carbohydrates
fiber, total dietary 13.9 _ _
Carbohydrates 64.8 63 g
Fats
22:6 n-3 fatty acid _ 0 _
(docosahexaenoic acid)
fatty acids, total monounsaturated 9.3 9.3 g
fatty acids, total polyunsaturated 1.2 0.85 g
total saturated fatty acids 16.9 16.8 g
12:0 fatty acid (lauric) 0.016 0 g
14:0 fatty acid (myristic acid) 0.045 0.03 g
16:0 fatty acid (palmitic acid) 8.432 8.69 g
18:0 fatty acid (stearic acid) 10.883 11.35 g
18:1 n-9 cis fatty acid (oleic acid) 8.013 11.15 g
cholesterol 9 0 mg
fatty acid 18:2 0.989 0.96 g
fatty acid 18:3 0.048 0.03 g
fatty acid 20:4 n-6 (arachidonic _ 0 g
acid)
20:5 fatty acid (eicosapentaenoic 0.003 0 g
acid)
Vitamins
Vitamin A retinol equivalents of 8.6667 2 ug
retinoid and carotenoid activities
Vitamin D 0 0 ug
Viamine E alpha tocopherol 0.1333 0.55 mg
equivalents of activities of vitamers
E
folate, total 6 10 ug
niacin equivalents, total 0.9667 0.6 mg
riboflavin 0.1367 0.15 mg
thiamine 0.0467 0.03 mg
B12 vitamin 0 0 ug
Vitamin B-6, Total 0.05 0.043 Mg
Vitamin C (ascorbic acid) 0 0 Mg
 Minerals
calcium 37.6667 63 mg
iron, total 1.5 2.8 mg
potassium 359.667 327 mg
magnesium 123.667 103 mg
sodium 12.3333 19 mg
match 181.333 147 mg
iodide 2.3 10 ug
selenium, total 6.8 2.8 ug
zinc (zinc) 2.2333 1.5 mg
Source taken: Spanish Food Composition Database. 2018 [42]

FORMAT AND PRESENTATION OF THE PACKAGING:

2.4 PHYSICOCHEMICAL ANALYSIS:

2.5 MICROBIOLOGICAL ANALYSIS: The presence of these pathogenic microorganisms
is analyzed: Total coliforms, Fecal coliforms, Aerobic mesophiles, Clostridium sulfite-
reducing spores, Molds and yeasts. Also, check the sterility of the bottle. Check that the
seeds do not contain fungi or weevils. In the process The extraction, pulp refining,
pasteurization and packaging operations must be carried out quickly because the pulps
oxidize easily and the flavor is altered. In the process, the pasteurization temperature and
time, as well as the cooling temperature, must be controlled.
2.6 ORGANOLEPTIC ANALYSIS: Sensory analysis test, Analyze product characteristics,
color, smell, flavor.
2.7 STORAGE CONDITIONS EXPIRATION DATE OR BEST CONSUMPTION DATE:

2.8 FORM OF CONSUMPTION AND CONSUMERS : edible, direct or indirect supply, this
product is intended for the general public.

2.9 APPLICABLE LEGISLATION:

RESOLUTION NUMBER 003929 OF 2013:

CODEX STAN 141-1983 (chocolate, cocoa powder): This Standard applies to Cocoa paste or
Cocoa/Chocolate Liqueur, and Cocoa Cake, as defined, for use in the manufacture of cocoa and
chocolate products. These products may also be sold directly to the consumer.

ISO 9000 Quality Management Standard.

ISO 22000 Food Safety Standard IFS, BRC Protocols also for Food Safety ISO 14000
Environmental Management Standard.

3. INTENDED USE OF THE PRODUCT

Table 3 Description of the final product and intended use

Product name Chocolate bar

Description Cocoa chocolate bar with sugar, preservative (methylparaben),
cinnamon. ground from a 5 m filter at 90°C for 2 minutes

Storage conditions In bulk, in tanks at reduced temperature until processing.

At room temperature during preparation.
Useful life Six months at room temperature. Once the container is opened,
it should be kept refrigerated and consumed as soon as
possible.
Expected use For consumption without further heating.
Packing In
Customer The acidity level is important for the flavor of the product.
specification Compliance with microbiological and mycotoxin guidelines.
Expected For domestic consumption and export. All age groups.
consumers

4. FLOW CHART OF THE APPLE NECTAR PRODUCTION PROCESS

Packaging Cocoa Sugar Cinnamon Preservative

Reception of materials

Storage in Store in a Stored in a

places with cool, dry dry place
Dry storage Stored at place not
refrigerati low humidity
and free of exposed
on to light
temperat pests
ure (0-
4°C)
 HAZARDS ASSOCIATED WITH CHOCOLATE BAR MANUFACTURING PROCESSES,
RESPECTIVE PREVENTIVE
Grinding MEASURES AND HAZARD EVALUATION:

GRAVITY OCCURRENCE

4 3 2 1
Very serious Yeah Yeah Yeah Yeah
I would be Yeah Yeah No No
moderate No No No No
Never No No No No

Stage Danger Description Gravity Probability Significance Preventive

 measure
Biological Possible presence I would be 3 Yeah -Return of fruits
of that are found
Cocoa reception Microorganisms, in with brown
cocoa there is a spots and lumps,
fungus called -Compliance
Moniliophthora with the
roreri that causes Supplier and
moniliasis in the Raw Materials
fruits. Brown spots Plan.
on the surface of
the fruit that later -Control of
become sporulated suppliers,
material of the accepting only
responsible fungus. fruits from crops
where pruning
and humidity are
controlled
Chemical Remains of I would be 2 No -Verify that
fungicide or other suppliers
pest control Implement good
substance, agricultural
contamination by practices.
mycotoxins
belonging to the -Cocoa quality
fungus. certificate.
-Control of the
dosage of
chemical
products.
Physical Presence of foreign I would be 1 No Visual
materials in the verification of
fruit. (Dust, dirt, purchased
splinters, etc.) fruits
Reception of biological Presence of I would be 3 Yeah Maintain
sugar microorganisms temperature
such as: Fecal above 80°C,
coliforms, sterilization
Escherichia coli conditions for
Enterobacteriaceae, pathogenic
Salmonella, organisms, In
Listeria due to addition,
poor sterilization temperatures of
or storage. more than
100°C reached
during the
evaporation
phase are
sufficient to
destroy
 pathogenic
spores
resistant.
Chemical Heavy metals, I would be 3 Yeah Control the use
s pesticides of pesticides in
sugar beet
cultivation.
Analyze the
concentration of
heavy metals
which should
not exceed that
established by
the codex for
arsenic lead 0.5
mg/kg
Water Physical Turbidity, presence Moderate 1 No Filtration and
of impurities compliance with
established
potability and
hardness
standards.
-Register of
Water treatment
and chlorination.
Chemical Atypical levels of I would be 1 No -Analytical
drinking water control of water.
components . -Specific water
circuits
Raw material Biological Change in the I would be 3 Yeah Control the
storage organoleptic temperature 0-4º
characteristics of C.
the product due to
high storage
temperatures that
can produce
degradation
reactions and, as a
result, harmful
substances.
Physicists local I would be 2 No -Maintenance
Poorly maintained. of premises in
hygienic
conditions.
Cocoa selection Biological Contamination by Moderate 1 No Visual
foreign matter, inspection of the
traces of mold raw material for
present on the the detection
outside and removal of
foreign
 materials, and
removal of fruits
in poor
condition.
Dry grains,
uniformly.

Chemical Moderate 1 No 1.75%

s maximum,
referring to
alkali-free (for
cocoa shell
only).

Heavy Biological Contamination I would be 1 No Maintenance

with of the teams
microorganisms used in
due to inadequate weighing that
cleaning of the have hygienic
equipment and conditions.
spaces used in the
cutting process.
Physical Incorporation of Moderate 1 No -Compliance
foreign material with the
due to inadequate maintenance
cleaning of the plan for
equipment and facilities and
spaces used in the equipment.
weighing process. -Calibration of
analytical scale
before the
production
process.
Washing cocoa Biological Quality Moderate 1 No Compliance
beans Inadequate water. with the
cleaning and
disinfection
plan.
Chemical Infiltration of I would be 2 No -Compliance
contaminants and with the
pathogens into the cleaning and
fruit. disinfection
Plan.

Drying in trays Physical Infiltration of I would be 3 No -Drying in

contaminating closed trays,
objects constantly
monitoring.
Manual removal Physical Presence of Moderate 2 No Supervision
of the shell material belonging after the process
 to the shell after is completed
the operation is
completed
Biological Incorporation of I would be 3 Yeah Good hygiene
pathogenic agents practices
due to inadequate
handling by Supervision of
personnel handling
personnel
Contamination by 3 Yeah Compliance
microorganisms with the
due to inadequate equipment
cleaning of the cleaning and
equipment. disinfection
plan.

Toasted Chemical Suitable Moderate 2 Yeah -Compliance

temperature with the plan
Grinding Physical Inadequate particle I would be 3 Yeah Sampling of the
size after the ground material
grinding process during the
process
Biological Presence of I would be 3 No Compliance
pathogens in with the
grinding maintenance
equipment plan for
facilities and
equipment

Compliance
with the
equipment
cleaning and
disinfection
plan.

DETERMINATION OF CRITICAL CONTROL POINTS (CCP) ACCORDING TO HAZARD

ANALYSIS USING THE DECISION TREE
 1. Reception of Raw Material.

1. Are there one or more control measures? Yeah.

2. Has the phase been specifically designed to eliminate or reduce to an acceptable level
the possible presence of one or more hazards? Yeah.
It's a PCC

2. Storage
1. Are there one or more control measures? Yeah.
2. Has the phase been specifically designed to eliminate or reduce to an acceptable level
the possible presence of one or more hazards? YEAH.
IF it is a PCC

3. Selection of cocoa
1. Are there one or more control measures? Yeah.
2. Has the phase been specifically designed to eliminate or reduce to an acceptable level
the possible presence of one or more hazards? Yeah.
IF it is a PCC.

4. Heavy
1. Are there one or more control measures? Yeah.
2. Has the phase been specifically designed to eliminate or reduce to an acceptable level
the possible presence of one or more hazards? Yeah.
IF it is a PCC

5. Cocoa Washing
1. Are there one or more control measures? Yeah.
2. Has the phase been specifically designed to eliminate or reduce to an acceptable level
the possible presence of one or more hazards? YEAH.
IF it is a PCC

5. Drying
1. Are there one or more control measures? Yeah.
2. Has the phase been specifically designed to eliminate or reduce to an acceptable level
the possible presence of one or more hazards? No.
3. Could the identified hazard(s) produce contamination above acceptable levels, or
increase it to unacceptable levels? Yeah.
4. Will the identified hazards be eliminated or their potential presence reduced to an
acceptable level at a later stage? Yeah.
NOT a CCP

6. Removed from the shell

1. Are there one or more control measures? Yeah.
2. Has the phase been specifically designed to eliminate or reduce to an acceptable level
the possible presence of one or more hazards? YEAH.
If it is a PCC

7. Toasted
1. Are there one or more control measures? Yeah.
2. Has the phase been specifically designed to eliminate or reduce to an acceptable level
the possible presence of one or more hazards? No.
3. Could the identified hazard(s) produce contamination above acceptable levels, or
increase it to unacceptable levels? No.
IF it is a PCC

8. Grinding
1. Are there one or more control measures? Yeah.
2. Has the phase been specifically designed to eliminate or reduce to an acceptable level
the possible presence of one or more hazards? Yeah.
IF it is a PCC
VERIFICATION PLAN OF THE HACCP SYSTEM FOR CRITICAL CONTROL POINTS IN
THE PREPARATION OF APPLE NECTAR.

1. Pasteurization
Activity Frequency Responsible Reviewer
Monitoring of Once per turn Head of HACCP Team
temperature manufacturing area
recording (manual or
automatic).

2. Storage
Activity Frequency Responsible Reviewer
Temperature Once per turn Head of storage area HACCP team
measurement should
be monitored using a
calibrated
thermometer,
preferably with a
continuous chart
recording system, and
storage duration
should be monitored
using a stopwatch.
 BIBLIOGRAPHY

1. alimentarius C. STANDARD FOR COCOA PASTE (COCOA LIQUOR/CHOCOLATE) AND

COCOA CAKE CODEX STAN 141-1983 [Internet]. CODEX STAN 141-1983; 2014 [cited 19
June 2019]. Available from: http://www.fao.org/input/download/standards/69/CXS_141s.pdf

2.