Manual on the application of the HACCP system in mycotoxin prevention and control

123 Pages·2001·3.1 MB·English

by  Food and Agriculture Organization of the United Nations

Manual on theapplication
ofthe HACCPsystem
in mycotoxin prevention
and control
Manualontheapplication FOODAFNAOD
ofthe HACCPsystem NUTRPIATPIEORN
in mycotoxin prevention 73
andcontrol
FAO/IAEATrainingandReferenceCentreforFood
andPesticideControl
MTERNATIONAL
ATOMICENERGY
AGENCY
aFnodod
AOgrrgiacnuilztautrieon
otUNfhnaeittleodna
Rome,2001
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©FAO2001
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FOREWORD
Mycotoxinsareconsideredtobeamongthemostsignificantfoodcontaminantswith
regardtotheirnegativeimpactonpublichealth,foodsecurityandthenational
economyofmanycountries,particularlythedevelopingones.Theyaffectawide
rangeofagriculturalproducts,includingcereals,driedfruits,nuts,coffeebeansand
oilseeds,whicharethebackboneofmostdevelopingeconomies. Thesemajorcrops
arehighlysusceptibletofungalcontaminationandmycotoxinproduction.Mycotoxin
contaminationofsusceptiblecommoditiesoccursasaresultofenvironmental
conditionsinthefieldaswellasimproperharvesting,storageandprocessing
operations.
TheHazardAnalysisCriticalControlPoint(HACCP)systemhasbeenincreasingly
andsuccessfullyappliedbythefoodindustryandbyofficialfoodcontrolauthorities
topreventandcontrolrisksassociatedwithpotentialcontaminationoffoodproducts
withpathogenicmicro-organismsandchemicaltoxicants.Foodsafetyprogrammes
routinelyuseinformationaboutthefactorsleadingtocontaminationtoestablish
preventiveandcontrolprocedures,thusprovidingtheconsumerwithasafe,
wholesomefoodsupply.
ThisManualwaspreparedbytheFoodandAgricultureOrganizationoftheUnited
Nations(FAO)andtheInternationalAgencyforAtomicEnergy(IAEA)throughtheir
jointFAO/IAEATrainingandReferenceCentreforFoodandPesticideControl.Its
mainaimistoprovideguidancetothosecountries/institutionswishingtoapplythe
HACCPapproachtomycotoxinpreventionandcontrol.
ThetextandcasestudieswerepreparedbyM.PineirooftheLaboratorioTecnologico
delUruguay,Ave.Italia6201,Montevideo,UruguayandM.Nagler,R.Coker,L.
Nicolaides,P.WareingandR.MyharaofNaturalResourcesInstitute,Universityof
Greenwich,MedwayUniversityCampus,CentralAvenue,ChathamMaritime,Kent
ME44TB.UnitedKingdom.Themanualbenefitedfromthepeerreviewand
commentsofM.Olson,SwedishNationalFoodAdministration,D.Park,University
ofLouisianaandE.Boutrif,FoodQualityandStandardsService.FAO.
TheexamplespresentedinthisManualhavebeenbasedonrealcasestudiesandaim
etompilhlausstirsaetedtthheataptphleisceaHtiAonCoCfPHpAlCanCsParsepeocnilfyiceaxlalmypfloersmayncdotaorexifnorcognutirdoaln.ceItamnudstbe
trainingonly.EveryHACCPplanmustbedevelopedfollowingthe12tasks,and
applyingthesevenprinciplesofHACCPasdefinedbytheCodexAlimentarius
Commission.ItisunlikelythatanytwoHACCPplanswillbeidentical,evenforthe
sameproduct.
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TABLEOFCONTENTS
Page
Preface U1
Chapter1: Anintroductiontomycotoxins 1
Whataremycotoxins? 1
Mycotoxicoloey-asystemsapproach 2
Mycotoxinsofworld-wideImportance 6
• Aflatoxins 7
•• TZreiacroatlheencoennees 11?
• OFciihmroantiosxiinnsA 1n?
• Patulin 15
Theco-occurrenceofmycotoxins 15
Mycotoxinsofregionalimportance 15
Chapter2: Anoverviewofhazardanalysisandcriticalcontrolpoint(HACCP) 25
Introduction 75
Pre-requisiteprogrammes 26
BasicprinciplesofHACCP 29
DevelopingaHACCPplan 30
ApplicationofHACCPtomvcotoxincontrol 36
Conclusions 41
AAppppeennddiixx11:1: TDeafsiknsitiinovnolovfetderinmsdevelopingHACCPsystem 4452
AppendixIII:ExampleofForm-Descriptionofaproductandofits
intendeduse 46
AppendixIV:AnexampleofdecisiontreetoidentifyCCPs 47
AppendixV; AnExampleofaHACCPWorksheet 48
Chapter3: IllustrativeexamplesofapplicationofHACCPtomvcotoxincontrol 49
Example1:Yellowmaizekernels-SouthEastAsia 51
Example2:Maize-basedAnimalFeed-SouthEastAsia 63
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Example3:Copracakeandmeal-SoutheastAsia 72
Example4:Commerciallyproducedpeanutbutter.SouthernAfrica 82
Example5:Applejuice(Appledrink)-SouthAmerica 91
Example6:PistachionutsinWestAsia 101
References 113
Listoftables:
Table1:Mouldsandmycotoxinsofworld-wideimportance 7
Table2:Mouldsandmycotoxinsofregionalimportance 16
Table3:Productdescriptionandintendeduseofyellowmaizekernels 52
Table4:HACCPPlanWorskheet-Aflatoxininyellowmaizekernelsforanimalfeed 60
Table5:Productdescriptionandintendeduseformaize-basedanimalfeed 63
Table6:HACCPPlanWorksheet:Maize-basedanimalfeed-SoutheastAsia 71
Table7:ProductdescriptionandintendeduseforCopracakeandmeal 73
Table8:HACCPPlanWorksheetforCopraby-products-SoutheastAsia 80
Table9:Productdescriptionandintendeduseforpeanutbutter-SouthernAfrica 83
Table10:HACCPPlanWorksheetforpeanutbutter-SouthernAfrica 89
Table11:DescriptionandintendeduseofApplejuice-SouthAmerica 92
Table12:HACCPPlanWorksheet-AppleJuice 95
Table13:Productdescriptionandintendeduseforpistachio-WestAsia 103
Table14:HACCPPlanWorksheetforPistachionuts,roasted-WestAsia 111
Listgffigurvs:
Figure1:TheCommoditySystem 3
Figure2:TheSpoilageSystem 4
Figure3:TheMvcotoxinSystem 6
Figure4:TheChemicalstructureofsomeimportantmycotoxins 8
Figure5:Thestructureofcyclopiazonicacid 10
Figure6:TheControlSystem L9
Figure7:FoodSafetyTools:anintegratedapproach 20
Figure8:HACCPFlow-diagram:YellowmaizeinSoutheastAsia 53
Figure9:HACCPFlow-diagram:Maize-basedfeedinSoutheastAsia 64
Figure10:VerifiedcommodityflowdiagramforCopracakeandmeal 74
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Figure11:HACCPFlow-diagramforPeanutButter-SouthernAfrica 84
Figure12;HACCPProcessFlow-diagramforapplejuice-SouthAmerica 93
Figure13:HACCPProcessFlow-diagramforpistachionuts,roasted 104
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Chapter1
ANINTRODUCTIONTOMYCOTOXINS
WHATAREMYCOTOXINS?
“...Wailingandwrithingmencollapsedinthestreet:othersfelloverandfoamedinepilepticfits
whilstsomevomitedandshowedsignsofinsanity.Manyofthemshouted“Fire!I’mburning”.
Itwasaninvisiblefirethatseparatedthefleshfromthebonesandconsumedit.Men.womenand
childrendiedinunbearableagonisingpain."..
Thesearethewordsusedbyatenthcenturychroniclertodescribeadiseasewhichaffectedmany
partsofEuropein943AD.Thediseasebecameknownas‘StAnthony’sfire’becauseofthe
burningsensationexperiencedbythevictims,manyofwhomvisitedtheshrineofStAnthonyin
Franceinthehopeofbeingcured.WenowknowthatStAnthony’sFire(ergotism)wascaused
bytheconsumptionofryecontaminatedwiththe‘ergotalkaloids’,producedbythemould
Clavicepspurpurea(Bove,1970;BeardallandMiller,1994),andthatitreachedepidemic
proportionsinmanypartsofEuropeinthetenthcentury.Toxicsecondarymetabolites,suchas
theergotalkaloids,whichareproducedbycertainmouldsarcdescribedas‘mycotoxins’,andthe
diseasestheycausearecalled‘mycotoxicoscs’.
AsrecentlydefinedbyPitt(1996),mycotoxinsare‘fungalmetaboliteswhichwheningested,
inhaledorabsorbedthroughtheskincauseloweredperformance,sicknessordeathinmanor
animals,includingbirds.’
Itislikelythatmycotoxinshaveplaguedmankindsincethebeginningoforganisedcrop
production.Ithasbeensurmised,forexample,thattheseveredepopulationofwesternEuropein
thethirteenthcenturywascausedbythereplacementofryewithwheat,animportantsourceof
Fusariummycotoxins(Miller,1991).ThedevelopmentoftheFusariumtoxinsinoverwintered
grainwasalsoresponsibleforthedeathofthousands,andthedecimationofentirevillages,in
SiberiaduringtheSecondWorldWar.Themycotoxicosislatterlyknownas‘alimentary'toxic
aleukia'(ATA)producedvomiting,acuteinflammationofthealimentarytract,anaemia,
circulatoryfailureandconvulsions.
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Mycotoxinsoccurmawidevanetyoffoodsandfeedsandhavebeenimplicated(Mayer.1953;
Coker,1997)inarangeofhumanandanimaldiseases.Exposuretomycotoxinscanproduce
bothacuteandchronictoxicitiesrangingfromdeathtodeleteriouseffectsuponthecentral
nervous,cardiovascularandpulmonarysystems,anduponthealimentarytract.Mycotoxinsmay
alsobecarcinogenic,mutagenic,teratogenicandimmunosuppressive.Theabilityofsome
mycotoxinstocompromisetheimmuneresponseand,consequently,toreduceresistanceto
infectiousdiseaseisnowwidelyconsideredtobethemostimportanteffectofmycotoxins,
particularlyindevelopingcountries.
Themycotoxinsattractworld-wideattentionbecauseofthesignificanteconomiclosses
associatedwiththeirimpactonhumanhealth,animalproductivityandbothdomesticand
internationaltrade.Ithasbeenestimated(Miller,Personalcommunication),forexample,that
annuallossesintheUSAandCanada,arisingfromtheimpactofmycotoxinsonthefeedand
livestockindustries,areoftheorderof$5billion.Indevelopingcountries,wherethefood
staples(e.g.maizeandgroundnuts)arcsusceptibletocontamination,itislikelythatsignificant
additionallosseswilloccuramongstthehumanpopulationbecauseofmorbidityandpremature
deathassociatedwiththeconsumptionofmycotoxins.
MYCOTOXICOLOGY-ASYSTEMSAPPROACH
A‘system’maybeviewedasasetofinteractingcomponents,wheretheinteractionsarejustas
importantasthecomponentsthemselves(afterOpenUniversity,1987).A‘systems’approachto
thecontrolofmycotoxinsutilises(Coker,1997)conceptualmodelsofinteractionsbetween,and
within,commodity,spoilage,mycotoxin,andcontrolsubsystems.Withinasystem,thesub-
systemscanfreelyinteract;inotherwords,activitywithinonesubsystemcaninfluenceeventsin
oneormoreothersub-systems.
Abetterunderstandingofboththeinteractionsandthecomponentsassociatedwiththesesystems
willassistinunderstandingtheaetiologyofmycotoxinproduction,andinformulating
appropriateinterventionsforthecontrolofmycotoxinsandmycotoxicoses.
THECOMMODITYSYSTEM
Anycommoditysystemiscomposedofnumerousinteractingtechnicalandsocio-economic
‘processes’including,forexample,pestanddiseasecontrol,harvesting,drying,processing,
marketing,creditandpricingpoliciesandculturalissues,tonamebutafew.Ageneralised,
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simplifiedcommoditysystemisrepresentedinFigure1whereselectedprocessesarerepresented
asinteractingsubsystems.
Figure1.TheCommoditySystem
OTHERCOMMODITYSYSTEMS
THECOMMODITYSYSTEM
AGRONOMY; HARVESTING PROCESSING
SPoeisltm&anDaisgeeamseenCtontrol
DRYING STORAGE
TRANSPORTATION MARKETING FINANCING
CONSUMPTION
Atanypointwithinthecommoditysystem,theconditionofthecommodityisdeterminedbya
complexmilieuinvolvingamultitudeofinteractionsbetweenthecrop,themacro-andmicro-
environmentandavarietyofbiological,chemical,physicalandsocio-economicfactors.A
changewithinanyoneprocesswillinvariablybringaboutchangesinoneormoreoftheother
processes.Actiontakenbeforeharvesttocontrolpestdamageand/orincreaseproduction(e.g
selectionofvarieties,timingofhanest)canhaveasignificantimpactonthepost-harvestquality
ofthecommodity.Hybridwhitemaize,forexample,hasmuchhigheryieldsthantraditional
varietiesbuthaspooron-farmstoragecharacteristics.Similarly,sinceitisveryrareforasingle
commoditysystemtoexistinisolationwithinagivenagro-climaticregion,itshouldbe
rememberedthatactivitieswithinonesystemcansignificantlyeffecteventsinothersystems.
Giventhefiniteresourcesoffarmers,forexample,anincreaseintheimportanceofone
commoditywillfrequentlyleadtotheallocationoflessresourcestowardsthecareofother
commodities.
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