SARAS SPICES - mini project

INDEX

o   Acknowledgment

o   INTRODUCTION

o   SARAS SPICES

o   FOOD AND DRUG ADMINISTRATION (FDA) of USA

o   Hazard Analysis and Critical Control Point (HACCP)

o   AGMARK of INDIA

o   SPICES BOARD OF INDIA

o   SPICE HOUSE CERTIFICATE

o   Product  of saras spices

o   Processing of some spices is given below:

·        Black Pepper

·        CARDAMOM

·        CHILLIES

·        Turmeric

o   Processing flow chart

o   Spices testing and inspection

·        Colour value of chillis & chilli oleoresin

     spectrophotometer

·        Ash analysis

·        Moisture Analysis

·        Volatile oil content (VOC)

·        Non volatile ether extract (NVEE)

·        Microscopic method for the detection of starch other than turmeric starch

·        Determination of salt

·        Commercial sterility

·        Commercial sterility test

·        Example for some lab tests

     Sambar powder

     Chicken masala

ACKNOWLEDGEMENT

      At the very outset we are very much grateful to God for his blessings showed up on us.

      We wish to acknowledge our sincere gratitude to Fr.Joseph kollamparambil, Principal, St.George’s College, Aruvithura.

      We are grateful to Mrs.Mini Michael, Head of department Food science & Quality Control and all teachers for the facilities and guidance to us for accomplish this training.

      We would like to express our sincere thanks to Mr. Boby M Jacob (MD),Mathi P E (Plant Manager), for their encouragement and giving us a chance to enter into the spices industry.

      We are indebted to record our heartful thanks to Mrs. Jasmi Shalu(Microbiologist),   Mr Renjith Jinadevan (Chemist), Mr Jaymon Joseph Chacko (R & D)

      We extent our extreme thanks to supervisors and the operators of each section for sharing their ideas with us.

                                                                              

                                                        NAZEEB V.P

                                                        JEFFIN THANKACHAN

INTRODUCTION

SARAS SPICES IN FORWARD PATH IN THE SILVER JUBILEE YEAR

Sara Spices, a sister concern of the trusted Kerala household name of Anna Aluminium, is in its silver jubilee year. The group founder Mr. M.C. Jacob named the company after his maternal aunt who always used to encourage him in his endeavors. When the company was inaugurated by the then Chief Minister of Kerala, Mr. P.K.Vasudevan Nair, there were few other curry powder manufacturers in the state. Now there are more than 250 different curry powder units of varying sizes. But the uniqueness of Saras lies in the fact that it has stood by the commitment to non-adulteration and high quality, as a crowning point of which the company retained the Agmark certification of Government of India all these years since inception.

As the curry powder revolution was spearheaded in Kerala 25 years back by Saras, so it is quite logical that Saras is again the first to bring out RTC gravies and RTE foods in traditional Kerala style. As the pace of life quickened with more ladies going for work, the traditional culinary art had to give way to easier methods. The highly convenient mixed spice powders took root in Kerala in the last few years. The avant-garde RTC / RTE technology makes cooking further simple and is sure to catch on in the market just as the curry powders did a few years ago. As RTE and RTC products, a wide variety of traditional Kerala food items will be available shortly on sale throughout Kerala. It is hoped that this silver jubilee gift from Saras will be well received by Keralites.

Mr. M.C. Jacob started the first company of his business group in 1968 as a small company of only eight employees. Now it has grown into the single largest private sector employer in Kerala with nearly 5000 employees. Anna Aluminium, Chakson Pressure Cooker, Chakson Thermal Cooker, Kitex, ScoobeeDay bags and Kitex Garments are all successful Anna Group companies.

SARAS SPICES

Spices have been intimately bound up with the very fabric of Indian life and culture. This has been so since human civilisation began. Indian spices have been witness to, and often participants in history being made and unmade. They have inspired perilous adventures, fuelled human greed, triggered momentous wars, forged lasting friendships and caused the discovery of unknown lands. To this day, Indian spices hold sway over millions around the world. SARA SPICES is the condiment producing unit of the Anna Group. It is involved in the production and exporting of Curry powders, Whole Spices, etc. for the past two decades. Since its inception in the year 1976, Sara Spices have come a long way, tingling the palates of gourmets the world over with its delicious range of Spices and Masala powders. Sara Spices and curry powders are known for its high standards of quality and hygiene and has won accolades at home as well as abroad.It was awarded the AGMARK, the hallmark of quality in India. Sara curry powders include Jeera, Cardamom, Ginger, Turmeric, Red Chilly and Coriander. A wide range of masala powder are also available under this brand; which include Meat masala, Sambar powder, Rasam powder, Fish masala, Idli Chutney, Garam masala, Pickle mix, Chicken masala, Vegetable masala, Chana masala, Pav Bhaji masala, Biriyani masala and Vindaloo masala. STERILIZED READY-TO-COOK GRAVY FOR EASY COOKING Saras is bringing out Ready to cook (RTC) gravies as the modern sequel to curry powders in terms of ease of cooking. If RTC gravy is available, cooking is delightfully simple. Just prepare the chopped pieces of vegetables, meat, fish or chicken, mix with the matching gravy and cook on fire in open container or pressure cooker until the pieces are fully cooked. That's it, the dish is ready.       STERILIZED READY TO EAT (RTE) FOOD Saras ready to eat products offer the convenience of anytime food. The variety of products on offer are traditional Kerala meat, fish, vegetable and fish curries, payasam, biriayani, etc. Acclaimed for the highest standards of quality, Sara Whole Spices and Curry Powders have been approved by : FOOD AND DRUG ADMINISTRATION (FDA) of USA. AGMARK of INDIA. RECOGNISED BY SPICES BOARD OF INDIA. SPICE HOUSE CERTIFICATE

 FOOD AND DRUG ADMINISTRATION (FDA) of USA

FDA regulates dietary supplements under a different set of regulations than those covering "conventional" foods and drug products (prescription and Over-the-Counter). Under the Dietary Supplement Health and Education Act of 1994 (DSHEA), the dietary supplement manufacturer is responsible for ensuring that a dietary supplement is safe before it is marketed. FDA is responsible for taking action against any unsafe dietary supplement product after it reaches the market. Generally, manufacturers do not need to register their products with FDA nor get FDA approval before producing or selling dietary supplements. Manufacturers must make sure that product label information is truthful and not misleading.

FDA's post-marketing responsibilities include monitoring safety, e.g. voluntary dietary supplement adverse event reporting, and product information, such as labeling, claims, package inserts, and accompanying literature. The Federal Trade Commission regulates dietary supplement advertising.

Domestic and foreign facilities that manufacture/process, pack, or hold food for human or animal consumption in the United States are required to register their facility with the FDA. For more information

Food Safety Widgets & Apps

The new Food Safety Alerts & Tips Widget is the first widget that compiles all food recall information from FDA and USDA in the same place.

Food Safety Programs

•Reportable Food Registry

•Action Plans

Product-Specific Information

•Acidified and Low-Acid Canned Foods

•Bottled Water & Carbonated Soft Drinks

•Cheese Safety

•Egg Safety

•Fruits, Vegetables & Juices

•Infant Formula

•Medical Foods

•Milk Safety

•Seafood 

Food Allergens

•Consumer Information

•Food Allergens Labeling   

Foodborne Illness

•Consumer Information

•Foodborne Illness, Foodborne Pathogens & Natural Toxins

•Interagency Coordination 

Food Contaminants & Adulteration

•Chemical Contaminants

•Metals

•Natural Toxins

•Pesticides 

Hazard Analysis & Critical Control Point (HACCP)

•HACCP Principles & Application Guidelines

•Dairy Grade A Voluntary HACCP

•Juice HACCP•Retail & Food Service HACCP

•Seafood HACCP 

Hazard Analysis and Critical Control Point (HACCP)

Adopted August 14, 1997

NATIONAL ADVISORY COMMITTEE ON
MICROBIOLOGICAL CRITERIA FOR FOODS

The National Advisory Committee on Microbiological Criteria for Foods (NACMCF) is an advisory committee chartered under the U.S. Department of Agriculture (USDA) and comprised of participants from the USDA (Food Safety and Inspection Service), Department of Health and Human Services (U.S. Food and Drug Administration and the Centers for Disease Control and Prevention) the Department of Commerce (National Marine Fisheries Service), the Department of Defense (Office of the Army Surgeon General), academia, industry and state employees. NACMCF provides guidance and recommendations to the Secretary of Agriculture and the Secretary of Health and Human Services regarding the microbiological safety of foods.

DEFINITIONS

CCP Decision Tree:

A sequence of questions to assist in determining whether a control point is a CCP.

Control:

(a) To manage the conditions of an operation to maintain compliance with established criteria.

(b) The state where correct procedures are being followed and criteria are being met.

Control Measure:

Any action or activity that can be used to prevent, eliminate or reduce a significant hazard.

Control Point:

Any step at which biological, chemical, or physical factors can be controlled.

Corrective Action:

Procedures followed when a deviation occurs.

Criterion:

A requirement on which a judgement or decision can be based.

Critical Control Point:

A step at which control can be applied and is essential to prevent or eliminate a food safety hazard or reduce it to an acceptable level.

Critical Limit:

A maximum and/or minimum value to which a biological, chemical or physical parameter must be controlled at a CCP to prevent, eliminate or reduce to an acceptable level the occurrence of a food safety hazard.

Deviation:

Failure to meet a critical limit.

HACCP:

A systematic approach to the identification, evaluation, and control of food safety hazards.

HACCP Plan:

The written document which is based upon the principles of HACCP and which delineates the procedures to be followed.

HACCP System:

The result of the implementation of the HACCP Plan.

HACCP Team:

The group of people who are responsible for developing, implementing and maintaining the HACCP system.

Hazard:

A biological, chemical, or physical agent that is reasonably likely to cause illness or injury in the absence of its control.

Hazard Analysis:

The process of collecting and evaluating information on hazards associated with the food under consideration to decide which are significant and must be addressed in the HACCP plan.

Monitor:

To conduct a planned sequence of observations or measurements to assess whether a CCP is under control and to produce an accurate record for future use in verification.

Prerequisite Programs:

Procedures, including Good Manufacturing Practices, that address operational conditions providing the foundation for the HACCP system.

Severity:

The seriousness of the effect(s) of a hazard.

Step:

A point, procedure, operation or stage in the food system from primary production to final consumption.

Validation:

That element of verification focused on collecting and evaluating scientific and technical information to determine if the HACCP plan, when properly implemented, will effectively control the hazards.

Verification:

Those activities, other than monitoring, that determine the validity of the HACCP plan and that the system is operating according to the plan.

HACCP PRINCIPLES

HACCP is a systematic approach to the identification, evaluation, and control of food safety hazards based on the following seven principles:

Principle 1: Conduct a hazard analysis.

Principle 2: Determine the critical control points (CCPs).

Principle 3: Establish critical limits.

Principle 4: Establish monitoring procedures.

Principle 5: Establish corrective actions.

Principle 6: Establish verification procedures.

Principle 7: Establish record-keeping and documentation procedures

Example of a Company Established HACCP Verification Schedule

Activity	Frequency	Responsibility	Reviewer
Verification Activities Scheduling	Yearly or Upon HACCP System Change	HACCP Coordinator	Plant Manager
Initial Validation of HACCP Plan	Prior to and During Initial Implementation of Plan	Independent Expert(s)(a)	HACCP Team
Subsequent validation of HACCP Plan	When Critical Limits Changed, Significant Changes in Process, Equipment Changed, After System Failure, etc.	Independent Expert(s)(a)	HACCP Team
Verification of CCP Monitoring as Described in the Plan (e.g., monitoring of patty cooking temperature)	According to HACCP Plan (e.g., once per shift)	According to HACCP Plan (e.g., Line Supervisor)	According to HACCP Plan (e.g., Quality Control)
Review of Monitoring, Corrective Action Records to Show Compliance with the Plan	Monthly	Quality Assurance	HACCP Team
Comprehensive HACCP System Verification	Yearly	Independent Expert(s)(a)	Plant Manager

Common Prerequisite Programs

The production of safe food products requires that the HACCP system be built upon a solid foundation of prerequisite programs. Each segment of the food industry must provide the conditions necessary to protect food while it is under their control. This has traditionally been accomplished through the application of cGMPs. These conditions and practices are now considered to be prerequisite to the development and implementation of effective HACCP plans. Prerequisite programs provide the basic environmental and operating conditions that are necessary for the production of safe, wholesome food. Common prerequisite programs may include, but are not limited to: 

Facilities.

The establishment should be located, constructed and maintained according to sanitary design principles. There should be linear product flow and traffic control to minimize cross-contamination from raw to cooked materials.

Supplier Control.

Each facility should assure that its suppliers have in place effective GMP and food safety programs. These may be the subject of continuing supplier guarantee and supplier HACCP system verification.

Specifications.

There should be written specifications for all ingredients, products, and packaging materials.

Production Equipment.

All equipment should be constructed and installed according to sanitary design principles. Preventive maintenance and calibration schedules should be established and documented.

Cleaning and Sanitation.

All procedures for cleaning and sanitation of the equipment and the facility should be written and followed. A master sanitation schedule should be in place.

Personal Hygiene.

All employees and other persons who enter the manufacturing plant should follow the requirements for personal hygiene.

Training.

All employees should receive documented training in personal hygiene, GMP, cleaning and sanitation procedures, personal safety, and their role in the HACCP program.

Chemical Control.

Documented procedures must be in place to assure the segregation and proper use of non-food chemicals in the plant. These include cleaning chemicals, fumigants, and pesticides or baits used in or around the plant.

Receiving, Storage and Shipping.

All raw materials and products should be stored under sanitary conditions and the proper environmental conditions such as temperature and humidity to assure their safety and wholesomeness.

Traceability and Recall.

All raw materials and products should be lot-coded and a recall system in place so that rapid and complete traces and recalls can be done when a product retrieval is necessary.

Pest Control.

Effective pest control programs should be in place.

Retail & Food Service HACCP 

Managing retail food safety embodies the principles of HACCP at retail and active managerial control on the part of industry. Regulators also play a role in maintaining a food safety system in retail food establishments. Cooperatively, regulators and industry can work together to understand the perspective of each and account for the variety of food preparation and service needs found in retail food establishments - from the facility with minimal food service to very complex operations that serve hundreds to thousands of meals daily.

Specific information is provided to assist the regulator and industry in meeting the needs for providing safe food to the consumer.

• Managing Food Safety: A Manual for the Voluntary Use of HACCP Principles for Operators of Food Service and Retail Establishments

• Managing Food Safety: A Regulator's Manual For Applying HACCP Principles to Risk-based Retail and Food Service Inspections and Evaluating Voluntary Food Safety Management Systems

 

AGMARK of INDIA AGMARK GRADE SPECIFICATIONS FOR SPICES

Introduction              Quality has been a tradition in the spice trade of India and to maintain this tradition and to be in keeping with modern developments in the field of standardization of agricultural produce. the Government of India has prescribed standards for almost all spices pepper. dry ginger. Cardamom. dry chillies. turmeric. garlic. coriander. fennel. fenugreek. cumin and celery seeds and curry powder are graded compulsorily under law before export. The grades adopted for various spices are those prescribed under the Agricultural Produce (Grading and Marking Act 1937); and these Grades are popularly known as Agmark Grades. The scheme of compulsory Quality Control and Preshipment Inspection on certain spices was introduced by the Government of India in 1963 and from then on. the scheme is being introduced to cover all the spices in a phased programme. The preshipment inspection scheme is operated by the Directorate of Marketing Inspection. Ministry of Agriculture. Government of India.           The grade specifications have been brawn up on the basis of age-old and familiar trade names such as Malabar Pepper. Alleppey Green Cardamom. Snnam Chillies. Alleppey Finger Turmeric. Cochin Dry Ginger etc.. so as not to disturb the traditional terms.    Detailed specifications have been prescribed in the rules taking into account the individual characteristics of the spices concerned and broadly based on physical characteristic. colour. size. density. moisture content. presence of extraneous matter. damaged produce etc. Importers of spices from India would be well advised to place orders on the basis of agmark grades or ascertain from the exporters the specific agmark grades of the spices proposed to be exported. In orders being placed on the basis of samples also. the specific grade under which such goods will be graded could be ascertained so tl porter is assured of the quality characteristics of the spices for which orders are placed. Agmark Registration is available for following products :-                 Seed less Tarmarind, Daried Edible Mushrooms, Saffron, Sheekakai powder, Kangra Tea, Agar Agar, Papain, Rice, Wheat Atta, Puhes, Cercals, Besan (Gramflour), Basmati Rice (Export), Suji and Maida, Grapes, Apples, Alphonso Mangoes-Export, Plants, Alphonso Mangoes Homeconsumption, Canned, Bottled fruits and fruit products citrus, Table potatoes, William Pears, Kanchan (Bathua), Mangoes, Home consumption, Seed potatoes, Table potatoes Table potatoes (Export), Water chestnuts. Coconuts, Curry Powder, Chillies, Cardamom, Coriander, Garlic, Ginger, Onions, Chillies powder, Poppy seeds, Turmeric, Pennel, Fenugreek and Clery seeds Cumin seeds, Pepper, Ajowain Seeds, (Whole), Sannhemp, Palmyra Fibres, Cotton, Aloe Fibres, Jute.and other products.

SPICES BOARD OF INDIA

The Quality Evaluation Laboratory of Spices Board was established in 1989. It provides analytical services to the Indian spice industry, monitors the quality of spices produced and processed in the country and analyse all the samples collected by the Board under the Compulsory inspection on Chillies, Chillies products and Turmeric powder exported from India. The Laboratory also established its first regional Quality Evaluation Laboratory at Mumbai during June 2008. The second regional Quality Evaluation Laboratory is being established at Guntur, Andhrapradesh.

The laboratory is certified by British Standards Institution, U.K. for the ISO 9001:2000 Quality Management System in 1997, ISO 14001:2004 Environmental Management System in 1999 and Accreditation under the National Accreditation Board for Testing & Calibration Laboratories (NABL) (under the ISO/IEC: 17025) in 2004. The Laboratory activities are fully computerized and linked with network since 1999. The Laboratory is also in the process of providing the web enabled result delivery in the immediate future. The Laboratory is divided into three divisions Viz. Chemistry Lab, Residue Lab and Microbiology Lab for the speedy and efficient handling of the analysis done on various parameters. 

» Quality policy Statement on ISO:14001:2004

» Quality policy Statement on ISO:9001:2000

» Quality policy Statement on ISO IEC 17025:2005

Bureau of Indian Standards (BIS)

BIS has prescribed quality standards for 16 spices, spice powders, concentrates and oleoresins. Spices Board actively interacts with BIS in finalizing standards for other spices and to upgrade the existing ones.

PFA

PFA Act and Rules are sought to be amended by overhauling both the conceptual framework as well as procedural formalities considered to be major hurdles in the proper implementation of the Act. Spices Board has interface with all the other agencies involved in amending the PFA Act and Rules.

Survey on Quality of spices

Te laboratory undertakes survey to assess the quality of spices produced at various levels as and when required. Samples collected from the major spice growing centers are analyzed for physical, chemical and microbial contaminants including pesticide residues and aflatoxin.

SPICE HOUSE CERTIFICATE

Application for grant of Spice House Certificate

The latest in the Board's campaign for quality upgradation is the introduction of the Spice House Certificate. The certificate is issued to those processors/exporters who have a genuine commitment to quality, and whose long-term objective is sustained export growth. The Spice House Certificate seeks to identify and recognise processors who have made investments in in-house processing facilities and infrastructure, and have the necessary competence to ensure consistent quality and reliability. These facilities cover all critical areas - cleaning, grading, processing, packaging and warehousing. A foolproof system of quality assurance should be employed at all stages of processing - from raw material selection to final shipping. The processors are also expected to maintain a high degree of sanitation in the plant, while the workers must observe absolute cleanliness and personnel hygiene.

Both the logo and the Spice House Certificate holders have quality upgradation as their ultimate objective, but with a basic difference in focus.

 Exporters of branded spices and spice products in consumer packs are the focal point of the logo programme. On the other hand, the certification programme aims at exporters of spices and spice products in bulk packing. The products covered by the certification programme include whole spices as well as value-added products like spice mixes, ground spices, curry blends, spice oils oleoresins and sterilized, dehydrated, pickled and candied spices.

  Spice House Certificate logo

                 

Product  of saras spices

Powder

·         Chilly powder

·         Coriander powder

·         Turmeric powder

·         Pepper powder

·         Sambar powder

·         Pickle powder

·         Rasam powder

·         Meat masala

·         Fish masala

·         Garam masala

·         Chicken masala

·         Vegetable masala

·         Biriyani masala etc…

Ready to cook (RTC)

·          Meat curry arappu

·         Fish curry arappu

·         Chicken curry arappu

·         Tandoori chicken curry arappu

·         Butter chicken curry arappu

·         Chicken biriyani arappu

·        Lamb bhuna gravy

·        Ginger garlic paste

·        varathara etc…

Ready to eat (RTE)

·         Vegetable biriyani

·         Milk ada payasam

·         Uluva kanji

·         Wheat milk payasam

·         Neipayasam

·         Whole milk payasam etc…

Processing of some spices is given below:

Curry Powder
India is the origin of curry, a name widely recognised all over the world. Because of varied physical form, aroma and flavour an individual spice does not produce the preferred flavour. Indian curry powder is the answer to it. Known as 'curry powder' to the Indians, or simply as 'curry' to the international consumer, the product is a careful blend of selected spices to add pep, flavour and aroma to a wide range of exotic dishes.
Spices are ground and mixed in certain definite proportions to produce curry powder. Some of the important ingredients in curry powder are coriander, turmeric, chillies, cumin, pepper, ginger, cinnamon, cassia, clove etc. It also contains and edible common salt and sometimes added starch. A wide range of products are covered under the category 'Curry'. This includes straight powder, mixed powder, curry powder, curry mixture, masalas, curry paste and seasoning.
Another Indian speciality is a full complement of spice mixes. These mixes impart a distinct flavour to a variety of food preparations such as tandoori chicken, fish, meat, vegetables, tea and noodles. India is the major supplier of high-quality curry powders and spice mixes to the world

Processing of some spices is given below:

Black Pepper

                       Limit of contaminants stipulated by importing countries

                       Pepper exported to USA shou Id conform to the cleanliness specification stipulated by the American Spice Trade Association (ASTA) and also the regulations enforced by the Food and Drug Administration (FDA),ASTA cleanliness specifications set limits for criteria such as number of dead insects in the sample analysed, amount of mammalian excreta, other excreta, percentage of weight of berries with mold and / or insect infestation and the extent of foreign matter present. Pepper imported into USA failing to meet these cleanliness specifications will be detained and subjected to reconditioning (cleaning to remove the defect) If defects can not be removed by reconditioning the ot may be destroyed or sent back to the country of its origin. In addition to ASTA cleanliness specifications pepper imported to USA has to comply with the Defect Action Level of FDA as and when prescribed.

FDA Defect Action Levels for Pepper comprise of:

Defect Action level a. Pepper Whole (I) Insect filth and/or mold Average of 1 % or more of berries by weight are insect infested and or moldly (2) Mammalian excreta Average of 1 mg or more of mammalian excreta per pound (3) Foreign matter Average of 1 % or more pickings and sifting by weight. (4) Microbial contamination Presence of Salmonella/ Arizona not allowed b. Ground Pepper (1) Insectfilth 475 or more insect fragments per 50gm (2) Rodent filth 2 or more rodent hair fragments per 50 gm

CARDAMOM

ASTA CLEANLINESS SPECIFICATIONS

Name of spice Whole insect dead by count Excreta Mammalian by mg/lb Excreta other by mg/lb Mold % by Wt Insect defiledl/ infested % by Wt. Extraneous Foreign matter % by Wt. Cardamom (Whole) 4 3 1.0 1.0 1.0 0.50

                       Besides this, FDA also administers, Surveillance programmes to monitor for pesticide residues in Spices, the US Environmental Protection Agency (EPA) prescribes tolerance levels for pesticide residues and the FDA enforces them through compliance programmes. EEC countries constitute a major market for Indian Spices. Most EEC countries import spices in accordance with prevailing food laws. The Netherlands have specifications for various quality parameters of spices. Germany has prescribed tolerance levels for pesticides residues. The German specifications are supposed to be the most stringent. The Dutch law also prescribes maximum residues for pesticides in spices. The food industry and spice processers in U.K. follow the limit for pesticides prescribed in the German specifications.

                       Most EEC countries have prescribed tolerance levels for Aflatoxin. German specification for Aflatoxin B I and B I + B2 + G I + G2 are 2ppb and 4 ppb respectively. Other European countries specify and for the presence of Aflatoxin B I which vary from I ppb to IOppb.

                       In all EEC countries, specifications for Salmonella in spices is absence in 25 gms. The food processing industry and spice grinders specify microbial load for each spice blend depending upon the end use.

CHILLIES

ASTA CLEANLINESS SPECIFICATIONS (Effective April 28, 1999)

Name of spice Whole insect dead by count/lb Excreta Mammalian by mg/lb Excreta other by mg/lb Mold % by Wt Insect defiledl/ infested % by Wt. Extraneous Foreign matter % by Wt. Chillies (Whole) 4 1 8.0 3.00 2.50 0.50

In addition to ASTA cleanliness specifications spices imported to USA should comply with the Defect Action Levels (DAL) of FDA. At present FDA Defect Action Levels for Chillies comprise:

Defect Action level Chillies (Capsicum) (Pods) Insect filth and/ mold Average of more than 3% of pods by weight are insect infested and / or moldy. Chillies (ground) Mold Insect filth Average mold count is more than 20% Average of more than 50 insect fragments per 25 gm. Rodent filth Average of more than 6 hairs per 25 gms.

                       Besides this, FDA also administers Surveillance programmes to monitor for pesticide residues in spices, . the US Environmental Protection Agency (EPA) enforces them through compliance programmes. EEC Countries constitute a major market for Indian Spices. Most EEC Countries import spices in accordance with prevailing food laws. The Netherlands have specifications for various quality parameters of spices. Germany has prescribed tolerance levels for pesticide residues. The German specifications are supposed to be the most stringent. The Dutch law also prescribes maximum residues for pesticides in spices. The food industry and spice processers in U.K. follow the limit for pesticides prescribed in the German specifications in the absence of U.K. Specifications.

                       Most EEC countries have prescribed tolerance levels

for Aflatoxin. German specification for Aflatoxin B 1 + B2 + G 1 + G2 are 2 ppb and 4 ppb respectively. Other European countries have prescribed the limits for Aflatoxin B 1 which vary from 1 ppb to 10 ppb.

                       In all EEC countries specifications for Salmonella in spices is absence in 25 gms. The food processing industry and spice grinders specify microbial load for each spice blend depending upon the end use.

Turmeric

Packing

Only new and clean bags should be used for packing dried

turmeric. It is preferable to use polythene laminated gunny bgas

Storage precautions

                       Turmeric should be stored ensuring protection from dampness. Dunnage should be provided to stack the packed bags to prevent moisture ingress from the floor. Care should be taken to stack the bags 50 to 60 cms. away from the walls.

                       No insecticide, should, under any circumstances, be used directly on dried turmeric. Stored turmeric should be subjected to periodic fumigation for which only authorised persons should be engaged.

                       Insects,rodents and other animals should be effectively prevented from gctting access to the premises where tUrmeric is stored. Stored turmeric should be periodically exposed to the Sun.

                       Insects, rodents and othcr animals should bc effcctively prevented from getting access to the premises where turmeric is stored. Stored turmeric should be periodically exposed to the sun.

                       If care is taken in all stages of cultivation, harvesting, post harvest handling, processing, packing, storage and transportation by following sound methods and practices we will be able to prevent contamination and deterioration of quality in any farm produce including turmeric and ensure consumer satisfaction.

                       Conformity to the quality requirements of the buying countries and price competitiveness are the key factors which determine our survival in the international market today. Improved productivity and quality will enhance the farmers income and increase the country's foreign exchange earnings much needed for our developmental activities.

                       The maxim 'produce,process and prosper' holds true in the case of exports of spices from India and turmeric is an excellent example. The message is eloquent - we have to produce more turmeric through higher production and improved productivity to meet the demands of the domestic and the export markets and should process it adopting good processing practices creating value addition and of course have to export the product meeting the requirements of the importing countries which in turn would lead to significant groWth in exports.

Processing flow chart

Receiving spices

                                                                

                                                                 Lab testing

                                                                

                                                    Mixing and cooking (drying)

                                                                     Milling

                                                                 Weighting

                                                                 Exhausting

                                                                   Sealing

                                                                  Retorting

                                                                 Unloading

                                                           Packing and labeling

                                                                    Storage

                                                                     Testing

                                                                Distribution

Spices testing and inspection

Te laboratory undertakes survey to assess the quality of spices produced at various levels as and when required. Samples collected from the major spice growing centers are analyzed for physical, chemical and microbial contaminants including pesticide residues and aflatoxin.

.

Services covered in the Spices Board registration include laboratory testing services for physical, chemical and microbiological parameters of spices and spice products.

Spices Laboratory Testing:

      Colour value of chillis & chilli oleoresin

      Ash. ASTA*

      Moisture

      Volatile Oil

      Ether Extract

      Detection of starch

      Microbiological tests

*ASTA is the American Spice Trade Association.

Spices Tested and Inspected include:

      Allspice

      Capsicums, Celery Seed, Cinnamon Cloves, Coriander, Cumin Seed

      Dehydrated Garlic, Dehydrated Onion, Dill Fennel Seed

      Ginger

      Mustard Seed, Mace

      Paprika, Pepper

      Spice Extractives

      Thyme, Turmeric etc…

Colour value of chillis & chilli oleoresin

A.    Apparatus : Spectrophotometer, Absorption cell, Standard glass filter, Pipette

spectrophotometer

Introduction

In chemistry, spectrophotometry is the quantifiable study of electromagnetic spectra. It is more specific than the general term electromagnetic spectroscopy in that spectrophotometry deals with visible light, near-ultraviolet, and near-infrared. Also, the term does not cover time-resolved spectroscopic techniques.

Spectrophotometry involves the use of a spectrophotometer. A spectrophotometer is a photometer (a device for measuring light intensity) that can measure intensity as a function of the light source wavelength. Important features of spectrophotometers are spectral bandwidth and linear range of absorption measurement.

The use of spectrophotometers spans various scientific fields, such as physics, chemistry, biochemistry, and molecular biology They are widely used in many industries including printing and forensic examination.

How it Works

 

The general makeup of a spectrophotometer.               Spectrophotometer

There are two major classes of devices: single beam and double beam. A double beam spectrophotometer compares the light intensity between two light paths, one path containing a reference sample and the other the test sample. A single beam spectrophotometer measures the relative light intensity of the beam before and after a test sample is inserted. Although comparison measurements from double beam instruments are easier and more stable, single beam instruments can have a larger dynamic range and are optically simpler and more compact.

The spectrophotometer quantitatively compares the fraction of light that passes through a reference solution and a test solution. Light from the source lamp is passed through a monochromator, which diffracts the light into a "rainbow" of wavelengths and outputs narrow bandwidths of this diffracted spectrum. Discrete frequencies are transmitted through the test sample. Then the intensity[disambiguation needed] of the transmitted light is measured with a photodiode or other light sensor, and the transmittance value for this wavelength is then compared with the transmission through a reference sample.

The most common spectrophotometers are used in the UV and visible regions of the spectrum, and some of these instruments also operate into the near-infrared region as well.

Visible region 400–700 nm spectrophotometry is used extensively in colorimetry science.

Use this instrument to measure the amount of compounds in a sample. If the compound is more concentrated more light will be absorbed by the sample; within small ranges, the Beer-Lambert law holds and the absorbance between samples vary with concentration linearly.

Samples are usually prepared in cuvettes; depending on the region of interest, they may be constructed of glass, plastic, or quartz.

1. The light source shines onto or through the sample.
2. The sample transmits or reflects light.
3. The detector detects how much light was reflected from or transmitted through the sample.
4. The detector then converts how much light the sample transmitted or reflected into a number.

Beer–Lambert law, also known as relates the absorption of light to the properties of the material through which the light is traveling.

B.     Reagent: Acetone

C.    Procedure

1.      Ungrounded capsicum must be ground to pass through U.S No.20 sieve.

2.      Weight 70 – 100 mg of sample and transfer to a 100 ml vol. flask.

3.      Fill to mark with acetone and stopper tightly .

4.      Shake flask rest 16 hr. at room temp. in dark.

5.      Shake flask and allow 2 min. for the particles to settle.

6.      Transfer a portion of the extract to the  spectrophotometer cell and measure the absorbance at 460 nm with acetone blank

7.      Determine absorbance of glass filter at 465 nm

D.    Calculation

1.      Instrument correction factor (IF)

NBS A at 465 nm Lab A at 465 nm

                                       IF = 

      

0.5229  / Lab A at 465 nm std. glass filter

                                   

                                                                    =

A of acetone ext. × 16.4 IF Sample weight in gm.

2.      Extractable ASTA color =

Procedure for oleoresins

1.      Mix sample well by shaking

2.      Weight 70 – 100 mg of sample and transfer it to a 100 ml  vol. flask

3.       Fill to mark with acetone and stopper tightly and shake well

4.      Rest for 2 min.

5.      Transfer a portion of the extract to the  spectrophotometer cell and measure the absorbance at 460 nm with acetone blank

6.      Determine absorbance of glass filter at 465 nm

Calculation for oleoresins

1.       Instrument correction factor (IF)

NBS A for glass filter at 465 nm  A of glass filter at 465 nm

                                                     IF =

0.5229  / A of glass filter at 465 nm std.

                         

                                                                     =

A of acetone ext. × 16.4 IF Sample weight in gm.

2.      Extractable ASTA color =

E.     Result and reporting

        Report the result to the accuracy of 0.0 ASTA unit

Ash analysis

                    An Ash test is used to determine if a material is filled. The test will identify the total in organic content. It cannot identify individual percentages in multi-filled materials without additional test procedures being performed. An ash test cannot be used to determine the percent carbon fiber or percent carbon black since carbon burns off during the Ash test.

Specimen size:

                    Six grams of sample is typically used, which represents three crucibles each containing two grams of sample. Smaller sample weights can be tested but accuracy diminishes with smaller sample sizes.

Procedure:

                    An Ash test involves taking a known amount of sample, placing the weighed sample into a dried / pre-weighed porcelain crucible, burning away the sample in an air atmosphere at temperatures above 550°C, and weighing the crucible after it is has been cooled to room temperature in a desiccator.

Data:

                    The Ash test result is expressed as % ash. The total ash content equals the weight of the ash divided by the weight of the original sample multiplied by 100%.

Muffle furnace

Crucible

 

Moisture Analysis

Moisture affects the processibility, shelf life, usability and quality of many products such as pharmaceutical substances, and foods. Information about and monitoring of moisture content is therefore very important. Most substances have an optimum moisture content for obtaining the best possible processing results and therefore attaining maximum quality.

Moisture is determined by Dean and Stark method the apparatus consists mainly of 3 parts. A distillation flask is 500 ml. toluene of boiling point 1100C is used on the media for distillation of water.

Procedure :

40 g of sample is transfer to the distillation flask. 100 ml of toluene is added and well mixed. The Dean and Stark apparatus is assembled and filled with toluene. The flask is heated at 1000C  for 1 hr. Till the entire moisture content in the sample is distilled and collected in side trap. A spiral copper wire is moved up and down in the condenser and receiver to separated the water from toluene. On cooling the receiver at room temp. the volume of water collected in the graduated side trap and read it.

Vol. of sample (reading) ×100 Wt. of sample

Calculation :

Moisture content    =                                                                

Dean and Stark apparatus

             

                                                                                                                             

Volatile oil content (VOC)

Procedure :

                 About 50 g of sample is taken an RB flask (1000 ml), 500 ml water is added and well mixed. 7-8 drops of silicon antifoaming agent is adding. Connected to the Clevenger trap apparatus and reflex condenser. Heat at 1000C for 4-5 hr. we get on oil level of the sample in the trap.

Reading obtained ×100×100 Wt. of sample(100-moister)

Calculation :

                     %  of volatile oil content (VOC) =

                    

Clevenger trap

Non volatile ether extract (NVEE)

                     About 2-3g of the sample is weighted in a filter paper. The filter paper with sample is folder and tied with a twine and put in a thimble and is extracted   with petroleum ether (B.P.60-800C) at 700C for 18-hrs.in a soxhlet extraction apparatus. The extraction is continued till the color of the either become clear. After removing the ether completely the flask is dried by keeping in an air oven at 1050C. Cooled in a dessicater and weighed. Repeat the procedure until the difference between two successive weighing less than 1 mg.

Wt. of  NVEE×100×100 Wt. of sample (100-moisture)

Calculation :

                     % of   Non volatile ether extract =

soxhlet extraction apparatus

                           

Microscopic method for the detection of starch other than turmeric starch

                     A small quantity of sample is taken in a small beaker and is washed with di ethyl ether and diconted for about 4-5 times for removing the color and allowed to dry. The slide is prepared by spreading very little powder on the slide. Wetting with 1-2 drops of glycerol 30 % and covering with slip. The prepared slide is examined under a microscope peculation shaped yellow crystal of turmeric starch is seen. Any other small white round crystals are all so seen it is clear that foreign starch is present. If no other crystals present the sample is pure

Determination of salt

                     About  1-2 gm of sample is weighed in crucible and ashed in muffle furnace .the ash is completely washed and filtered throw ordinary filter paper with about 100 ml  boiling water. Until the filtrate become chloride free and tested by AgNo3 solution. The washing are collected in a conical flask and titrated against standard AgNo3 solution by adding 5 ml of 5 % of potassium chromate solution as an indicator. End point is the color change from yellow to biscuit red color. Titrations are repeated till concordant value are obtaine.

Calculation:

5.85×titar value×0.1× 100 Wt. of sample (100-moisture)

                    

                     % salt =       

Commercial sterility

Packaged in a sterile container in a way which maintains sterility

                  Sterility is achieved with a flash-heating process (temperature between 195° and 295°F (91° to 146°C)), which retains more nutrients and uses less energy than conventional sterilization techniques such as retort or hot-fill canning. Aseptic food preservation methods allow processed food to keep for long periods of time without preservatives, as long as they are not opened. The aseptic packages are typically a mix of paper (70%), polyethylene (LDPE) (24%), and aluminum (6%), with a tight polyethylene inside layer.[1] Together the materials form a tight seal against microbiological organisms, contaminants, and degradation, eliminating the need for refrigeration.

                  Aseptic processing makes worldwide export and import of new, economical and safe food products possible. Bag-In-Box technology is commonly used because it provides strong containers that are light weight and easy to handle prior to being filled. Other common package types are drink boxes and pouches.

Commercial sterility test

                  The thermally processed samples to different F0 were incubated at 37°C for 15 days and 55°C for 5 days. The incubated cans were aseptically opened and 1-2gm of the sample were taken by a sterilized forceps and inoculated into the sterilized fluid thioglycolate broth in test tube. Little sterilized liquid paraffin was put on to the top of the broth to create anaerobic condition and incubate  at 37°C for 48 hrs and at 55°C for 4 days. 

Example for some lab tests

Sambar powder

Lot no :

Date of sampling :

Date of completion of analysis :

Date of packing :

1.      volatile oil content (VOC)

         Wt. of sample                   = 50 g

         Reading obtained              = 0.3 ml

         % of volatile oil content    = 0.3×100     = 0.6%

                                                         50

2.      salt

         Wt. of sample                    = 1.087 g

         Titer wt of sample             = 8.3 ml

         % salt                                = 5.85×8.3×0.1×100      = 4.65%

                                                            1.087×96

3.      moisture

         Wt. of sample                    = 40 g

         Reading obtained              = 1.6 ml

         % of moisture                    = 1.6×100     = 4%

                                                         40

4.      crude fiber                                 

         Wt. of sample                    = 2.5134 g

         Wt. CF before ignition      = 33.1454 g

         Wt. CF after ignition        = 32.8435 g

         Wt. of CF                          =     0.302 g

           % of CF                          = 0.302×100×100    = 12.52%

                                                         2.5134×96

5.      Non volatile ether extract ( NVEE)

         Wt. of sample                    = 2.5134 g

         Wt. of empty flask            = 104.6500 g

         Wt. NVEE+flask              =104.9600 g

         Wt. of NVEE                    =0.31 g

         %NVEE                            = 0.31×100×100      = 12.96 %

                                                            2.5134×96

Chicken masala

Lot no :

Date of sampling :

Date of completion of analysis :

Date of packing :

1.      volatile oil content (VOC)

         Wt. of sample                   = 50 g

         Reading obtained              = 0.3 ml

         % of volatile oil content    = 0.3×100     = 0.6%

                                                         50

2.      salt

         Wt. of sample                    = 2 g

         Titer wt of sample             = 2.1 ml

         % salt                                = 5.85×2.1×0.1×100      = 0.64%

                                                            2×95.5

3.      moisture

         Wt. of sample                    = 40 g

         Reading obtained              = 1.8 ml

         % of moisture                    = 1.8×100     = 4.5%

                                                         40

4.      crude fiber                                 

         Wt. of sample                    = 2.3216 g

         Wt. CF before ignition      = 29.3560 g

         Wt. CF after ignition        = 29.0480 g

         Wt. of CF                          =     0.308 g

           % of CF                          = 0.308×100×100    = 13.89%

                                                         2.3216×95.5

5.      Non volatile ether extract ( NVEE)

         Wt. of sample                    = 2.3216 g

         Wt. of empty flask            = 101.1195 g

         Wt. NVEE+flask              =101.4485g

         Wt. of NVEE                    =0.329 g

         %NVEE                            = 0.329×100×100    = 14.84 %

                                                            2.3216×95.5