Experiences in the application of HACCP to traditional food processing at a semi-commercial kenkey production plant in Accra, Ghana

Abstract

Hazard Analysis Critical Control Point was implemented at a traditional semi-commercial plant for processing maize into Kenkey. The quality system was assessed for its effectiveness over a two months period, involving evaluation of the resident microbiota in the air and on the surface of processing equipment on three separate occasions, monitoring of Kenkey production on two occasions and laboratory analysis of raw materials, intermediary and final product on two separate occasions as a means of verification. Air sampling revealed a population of aerobic mesophiles ranging between 23 and 45 cfu/min; and yeasts and moulds between 12 and 16 cfu/min. The population of aerobic mesophiles on the surface of the steeping tank between batch productions was between 3.1 x 105 and 1.3 x 106 cfu/g; count on MRS between 4.6 x 105 and 5.7 x 105 cfu/g; and yeasts and moulds between 7.7 x 103 and 3.1 x 10" cfu/g. The fermentation trough also recorded aerobic mesophilic population ranging between 4.1 x 104 and 6.1 x 105 cfu/g; MRS counts between 2.1 x 103 and 5.0 x 106 cfu/g; and yeasts and moulds counts between 2.6 x 103 and 8.4 x 103 cfu/g. The aerobic mesophiles found at the plant included Bacillus spp., Staphylococcus spp. and Micrococcus spp. The lactic acid bacteria population was composed of Lactobacillus fermentum and pediococci; and the mou1ds Aspergillus spp., Mucor spp., Penicillium spp. and Fusarium spp. Very little variation was observed between the monitoring results on the two separate occasions and they all fell within the stipulated critical limit in each instance. Laboratory analysis showed the presence of coli forms and E. coli in the steep-water on the first occasion of sampling but could not be detected after 24 h of dough fermentation. Of the pathogens tested for on the second occasion of sampling, E. Coli, Staphylococcus aureus, Enterococcus, Salmonella, and Vibro cholera were not detected in any of the fermented maize dough and Kenkey samples analysed. Bacillus cereus was found in the fermented dough but was not detected after cooking into Kenkey. The level of total aflatoxin in the maize samples were 17.0 and 13.72 ug/kg and in the Kenkey samples 17.2 and 14.7 ug/kg. Levels of aflatoxins in Kenkey reported at the plant before implementation of HACCP ranged from 64.1 to 196 uglkg