The aim of this study is implementation of Hazard Analysis and Critical Control Points (HACCP) system during production of Egyptian Kishk on small scale production. Kishk is a traditional dry fermented product consisted from salted sour butter milk (Laban zeer) or yoghurt with cracked and bran free parboiled wheat grains (Burghol); the mixture of cereal and milk allows fermenting at ambient temperature for different periods, then the fermented mixture is formed in ball form and dried. Kishk is consumed in Egypt and in most Arab countries. Since Kishk is prepared by traditional and consumed widely, safety of this product is very important in terms of consumer health. Therefore, HACCP system as food safety tool was adopted during preparation of Kishk. Hazard analysis of raw materials and during different production steps was established. A simple HACCP plan was implemented; critical control points of production were determined; critical limits, corrective actions and monitoring procedures for each critical control points were established; verification procedures were also discussed.
According to National Advisory Committee on Microbiological Criteria for Foods [
Kishk is one of the traditional fermented food products in Egypt. It is a mixture of fermented milk with wheat grains and stored in the form of dried balls. Kishk is a balanced food with excellent storage stability, [
Differences in the preparation methods of Kishk and the cereal used can affect the composition, nutritional properties and microbiological characteristics of the final product [
Four types of cereals e.g. Local and imported wheat (Triticum astevium) grains were kindly obtained from Saudi Grains Organization (SAGO), Buraidah, Qassim region during the summer of 2015. Barley (Hordeum valgare) grains and pearl millet (Pennisetum glaucum) grains were purchased from the local market, Buraidah, Qassim region. Cow milk and goat milk used in yoghurts preparation were obtained from the Agriculture and Veterinary Research and Experiments Center followed Qassim University. Starter cultures were obtained from Christian Hansen (Copenhagen, Denmark) was Yo-flex culture (Yc-183), which is a mixed strain culture of Streptococcus thermophilus and Lactobacillus delbrueckii subsp. Bulgaricus at a ratio 1:1. The reagents used for the chemical analyses were of analytical grade.
Different Kishk samples were prepared from cow or goat milk with imported local wheat, barley or millet grains and the abbreviation codes of Kishk samples are listed in
Kishk code | Raw materials used in Kishk preparation* |
---|---|
CW1 | Cow yoghurt with imported wheat grains |
CW2 | Cow yoghurt with local wheat grains |
CB | Cow yoghurt with barley grains |
CM | Cow yoghurt with millet grains |
GW1 | Goat yoghurt with imported wheat grains |
GW2 | Goat yoghurt with local wheat grains |
GB | Goat yoghurt with barley grains |
GM | Goat yoghurt with millet grains |
*grain: yoghurt ratio is 1:4.
Kishk samples were illustrated by
Water activity of Kishk samples was determined using AQUA LAB (model series 3), USA by methods described by Landrock and Proctor (1951) [
Different prepared Kishk samples were microbiologically analyzed after preparation. Different Kishk samples (10 g from each) were aseptically taken, homogenized in 90 ml of sterile diluent (0.1% peptone water) with a Stomacher (Seward, Model 400, England) for 30 sec., serial dilutions were prepared in peptone water, IDF (1992) [
Kishk samples were examined for total viable bacterial counts, ADPI (1990) [
According to the (NACMCF, 1998) [
implemented during different preparation steps of Kishk samples based on the following seven principles: 1) Conduct a hazard analyses; 2) Identify the critical control points (CCPs); 3) Establish critical limits for preventive measures associated with each identified CCP; 4) Establish CCP monitoring requirements; 5) Establish corrective actions to be taken when monitoring indicates then a deviation from an established critical limit; 6) Establish verification procedures and 7) Establish record-keeping and documentation procedures. The results were summarized with reference to CCPs and their monitoring on the HACCP worksheet.
Water activity, acidity and pH of Kishk were expressed as the means ± SE. Statistical analysis was carried out using the PROC ANOVA followed by Duncan’s Multiple Range Test with p ≤ 0.05 being considered statistically significant to compare between means according to Snedecor and Cochran (1980) [
Egyptian Kishk is a mixture of fermented milk and wheat. It is a dry fermented food made from Laben zeer (salted sour buttermilk) or yoghurt with bulgur (cracked and bran-free parboiled wheat) and allows the mixture to ferment at ambient temperature for different periods. Kishk consumed in Egypt and in most Arab countries [
Each ingredient used in preparation of different Kishk samples and preparing steps were analyzed with taken into consideration individually in terms of HACCP system. Possible biological, chemical and physical hazards of Kishk ingredients and preparation steps were identified and listed in
Kishk samples | pH | Acidity | Water activity |
---|---|---|---|
CW1 | 4.81 ± 0.01b | 1.32 ± 0.04d | 0.34 ± 0.08ab |
CW2 | 4.84 ± 0.01a | 1.27 ± 0.02e | 0.31 ± 0.02d |
CB | 4.63 ± 0.16d | 1.38 ± 0.01b | 0.34 ± 0.01ab |
CM | 4.39 ± 0.08f | 1.50 ± 0.03a | 0.33 ± 0.05bc |
GW1 | 4.82 ± 0.17ab | 1.29 ± 0.04e | 0.32 ± 0.08c |
GW2 | 4.84 ± 0.20a | 1.27 ± 0.02e | 0.31 ± 0.04d |
GB | 4.69 ± 0.18c | 1.35 ± 0.11c | 0.35 ± 0.07a |
GM | 4.42 ± 0.04e | 1.48 ± 0.03a | 0.35 ± 0.05a |
Data are the mean ± SE, n = 3, Means having the same letter within each property are not significant difference at (p ≥ 0.05).
Preparation step | Hazard | Control measures | ||
---|---|---|---|---|
Biological | Chemical | Physical | ||
Receiving of wheat, barley and millet grains and yoghurt and salt. | Pathogenic bacteria, spore forming bacteria and yeast and mold. | Mycotoxins, pesticides residues and heavy metals. | Different impurities and foreign materials. | Certified suppliers, complains with raw materials specifications and good manufacturing practices. |
Cleaning of grains. | Non | Non | Different impurities and foreign materials. | Maintains of sieves, sanitation standard operating procedures and good manufacturing practices. |
Blanching of wheat and barley grains. | Non | Non | Non | Non |
Steam boiled of millet grains. | ||||
Remove of starch from grains. | ||||
Drying of cereal grains. | Pathogenic bacteria spore forming bacteria and yeast and mold. | Non | Different impurities and foreign materials. | Maintains of drying conditions (e.g. drying temperature and velocity of air) and good manufacturing practices. |
Cracked and dehulling of dried grains. | Non | Non | Different impurities and foreign materials. | Maintains of sieves and good manufacturing practices. |
Mixing of burghol with yoghurt and salt. | Pathogenic bacteria, spore forming bacteria and yeast and mold. | Non | Foreign materials. | Sanitation standard operating procedures, good manufacturing practices, acidity of yoghurt and concentration of salt. |
Incubation of the mixture. | Pathogenic bacteria, spore forming bacteria and yeast and mold. | Non | Non | Sanitation standard operating procedures, good manufacturing practices, acidity, pH and concentration of salt in the mixing. |
Mixing the mixture with rest of yoghurt. | Pathogenic bacteria, spore forming bacteria and yeast and mold. | Non | Foreign materials. | Sanitation standard operating procedures, good manufacturing practices, acidity, pH and concentration of salt in the mixing. |
Kishk formed and dried. | Pathogenic bacteria, spore forming bacteria and yeast and mold. | Non | Foreign materials. | Sanitation standard operating procedures, good manufacturing practices, acidity, pH, concentration of salt and water activity of Kishk. |
Kishk packaging and stored. | Non | Non | Non | Non |
Mycotoxins, pesticides residues, heavy metals and different impurities, foreign materials were identified as chemical and physical hazards, respectively. Control measures could be used in controlling the aforementioned hazards could be identified as certified suppliers of raw ingredients complains with raw materials specifications and good manufacturing practices (GMPs). So, the receipt of raw ingredients used in Kishk preparation is in accordance with the standards and requirements of the particular source of regulations and circulars issued by the Ministry of Municipal and Rural Affairs, www.momra.gov.sa, Saudi Food & Drug Authority and www.sfda.gov.sa. At the same time, microbiological, chemical and physical characteristics of ingredients used in preparing Kishk samples should be under the upper limits given in Guides of microbiological specifications and criteria for foods & harmful residues in food. As found in
Critical control points (CCPs) are processing step where control measures could be performed to prevent, eliminate and reduce any identified hazards (biological, chemical and physical) to an acceptable level, [
Critical limits of each identified CCP during preparation Kishk were determined. The critical limits of receiving raw ingredients should be listed in supplier guarantee specifications of each ingredients established by Ministry of Municipal and Rural Affairs, www.momra.gov.sa and Saudi Food & Drug Authority, www.sfda.gov.sa. So levels of different hazards in raw ingredients should be under the maximum values listed in guides of microbiological specifications and criteria for foods & harmful residues in food (www.momra.gov.sa). At the same time, microbiological, chemical and visual inspections of all raw materials should be taken into consideration according to established HACCP plan. Sieved grains should not contain physical hazards was the critical limit of cleaning grains step. The conditions of incubation and drying steps as temperature & time were established as critical limits for incubation and drying steps during preparing Kishk product. Temperature and time of incubation were 40˚C ± 2˚C and 24 hr, respectively, where their values were 50˚C ± 2˚C and 24 hr, respectively for drying step.
Preparation step | Decision tree questions* | CCP | Hazard | |||
---|---|---|---|---|---|---|
Q1 | Q2 | Q3 | Q4 | |||
Receiving wheat, barley and millet grains and cow or goat yoghurt and salt. | Yes | Yes | - | - | CCP | Biological, chemical and physical. |
Cleaning of grains. | Yes | Yes | - | - | CCP | Physical |
Blanching of wheat and barley grains. | Yes | No | No | - | - | - |
Steam boiled of millet grains. | Yes | No | No | - | - | - |
Remove of starch from grains. | Yes | No | No | - | - | - |
Drying of grains. | Yes | No | No | - | - | - |
Cracked and dehulling of dried grains. | Yes | No | No | - | - | - |
Mixing of burghol with yoghurt and salt. | Yes | No | No | - | - | - |
Incubation of mixture. | Yes | Yes | - | - | CCP | Biological |
Mixing the mixture with rest of yoghurt. | Yes | No | No | - | - | - |
Kishk formed and dried. | Yes | Yes | - | - | CCP | Biological |
Kishk packaging and stored. | Yes | No | No | - | - | - |
*: NACMCF (1998). Q1: Do preventative control measures exist? Q2: Is the step specifically designed to eliminate or reduce the likely occurrence of a hazard to an acceptable level? Q3: Could contamination with identified hazard(s) occur in excess of acceptable levels? Q4: Will subsequent step(s) eliminate or reduce the hazard to an acceptable level?
Visual inspection of supplier guarantee for each ingredient and cleaned grains could be established as monitoring procedures for CCPs of receiving raw ingredients and cleaning grains, respectively. Where checking temperature and time of incubation and drying steps (third and fourth CCP during Kishk preparing) could be used as monitoring procedures for these CCPs. At the same time, measuring pH, acidity and water activity of dried Kishk could be used as monitoring procedure for the same aforementioned two steps.
Different corrective actions for each identified CCP were established. A corrective action for the receiving raw ingredients used in preparation Kishk was reject any doubtful ingredients as it not accompanied by supplier guarantee. Re-sieved cleaned grains are the corrective action should be taken for cleaning grain step if any physical hazards are seen visually. Check and repair incubation and drying conditions (temperature and time) and reprocess if necessary were the corrective actions could be established when monitoring procedures of incubation and drying steps had been indicated that, the critical limits of those steps were exceeded.
The verification procedures for each identified CCP were established. Auditing of supplier guarantee and Visual inspection of characteristics for each ingredient were the verification procedures could be established for verifying receiving raw ingredients step. Test and visual inspection of sieves were the verification procedures for the step of cleaning grains during preparation Kishk. Regarding to incubation and drying steps, checked the conditions of incubation and drying steps (temperature and time) could be taken as verification procedures for verifying the aforementioned two CCPs. The incubation and drying steps were performed especially for controlling the safety of Kishk as pH, acidity and water activity of the product were sufficient for controlling microbial growth especially pathogenic bacteria, spore forming bacteria, yeast and mold, [
Kishk samples | Microbiological analysis (Log CFU/g) | |||
---|---|---|---|---|
Total bacterial count | Lactic acid bacteria | Coliform count | Yeast and molds | |
CW1 | 7.30 | 7.88 | ≤1 | ≤1 |
CW2 | 7.50 | 7.83 | ≤1 | ≤1 |
CB | 6.08 | 6.80 | ≤1 | ≤1 |
CM | 5.15 | 6.08 | ≤1 | ≤1 |
GW1 | 7.25 | 7.80 | ≤1 | ≤1 |
GW2 | 7.49 | 7.79 | ≤1 | ≤1 |
GB | 5.90 | 6.79 | ≤1 | ≤1 |
GM | 5.20 | 6.04 | ≤1 | ≤1 |
≤1: viable colony was not detected at detection limit < log CFU/g.
(2:1) and they found that preparation Kishk inhibited the growth of molds, yeasts and spore forming bacteria.
Finally it could be reported that, the low microbial load in the different prepared Kishk samples reflect the high sanitary conditions during the different preparing stages and no post-production contamination was occurring.
Record keeping documents for each identified CCP during preparation Kishk samples were presented in
Finally it could be reported that,
CCP | Hazard | Critical limits | Monitoring | Corrective actions | Verification | Record keeping |
---|---|---|---|---|---|---|
Receiving wheat, barley and millet grains and cow or goat yoghurt and salt. | Biological, chemical and physical | Supplier guarantees specifications of ingredients. | Visual inspection of supplier guarantee and sensory characteristics of each ingredient. | Reject any doubtful ingredients. | Auditing of supplier guarantee and visual inspection of characteristics for each ingredients. | Supplier guarantee |
Cleaning of grains. | Physical | Sieved grains should not contain physical hazards. | Visual inspection of cleaned grains. | Grains should be re-sieved if any physical contaminants are seen visually. | Test and visual inspection of sieves. | Reports of visual inspection of cleaned grains and testing of sieves. |
Incubation of mixture. | Biological | Compliance with general recommendation of good manufacturing practices. Temperature of incubation 40˚C ± 2˚C for 24 hrs. | Checked of temperature and time of inculpation and pH of cereals/yoghurt mixture. | Check and repair incubation conditions and reprocess if necessary (increase time of incubation). | Checked the incubation conditions and the final pH of cereals/yoghurt mixture. | Reports of checked temperature and time of inculpation and pH of cereals/yoghurt mixture. |
Kishk formed and dried. | Biological | Compliance with general recommendation of good manufacturing practices. Temperature of drying 50˚C ± 2˚C for 24 hrs. | Checked temperature and time of drying process and pH, acidity and water activity of Kishk. | Check and repair drying conditions and reprocess if necessary (increase time or temperature of drying). | Checked the drying conditions and testing the pH, water activity, acidity and microbiological load of Kishk. | Reports of checked the drying conditions and testing the pH, water activity, acidity and microbiological load of Kishk. |
viously listed in
Kishk is known as fermented milk-wheat mixture; salted sour buttermilk and different types of cereals could be used in preparing the Kishk like barley and millet. Since Kishk is widely consumed, it is important to establish an affective food safety system as HACCP during preparation of Kishk for improving the safety and protection of the consumer. The results of our study showed that the use of good quality raw ingredients and controlling system was very important during production of Kishk. HACCP system is needed in order to improve the safety of prepared Kishk. HACCP system could evaluate the different sources of hazards during various preparation steps of Kishk and control its critical control points occurring by applying HACCP system.
Abd El-Razik, M.M., Hassan, M.F.Y. and Gadallah, M.G.E. (2016) Implementation of HACCP Plan for the Production of Egyptian Kishk (A Traditional Fermented Cereal-Milk Mixture). Food and Nutrition Sciences, 7, 1262-1275. http://dx.doi.org/10.4236/fns.2016.713116