Contents Management of food allergen: Industry case study 1. Introduction of Morinaga Institute 2. Importance of food allergen labeling 3. Practical food allergen management Masahiro Shoji Morinaga Institute of Biological Science, Inc. 4. Conclusion 1 2 Who is Morinaga Institute? Morinaga Institute of Biological Science is the affiliate of Morinaga and Co., Ltd., the leading food company in Japan, manufacturing; 1. Introduction of Morinaga Institute 3 4
What activity Morinaga Institute is doing? Responsible for biotechnology business in Morinaga group Produce food safety products, utilizing ELISA and Lateralflow technology. Morinaga food allergen kits Official food allergen test kits in Japan 2. Importance of food allergen labeling Morinaga Bio-science (Thailand) Co. is manufacturing our food allergen kits in Thailand. 5 6 Food allergy: The global issue Fatal health hazard Increase of the patient number globally Higher prevalence in baby and infant No complete medication for food allergy Food allergic accident can be prevented by the avoidance of offending food allergen by the patient. 7 Food allergen labeling regulation According to the regulation, the food allergic patients can choose their safe food by checking product label. The regulation aims to contribute the better food life of food allergic patient. 8
R&D Food allergen management Label food allergen correctly on product label Factory 3. Practical food allergen management Formulation Production & Packaging Receiving raw material Releasing product Un-intentional inclusion of food allergen! Monitoring Monitoring Monitoring 9 10 Amaranth biscuit for food allergic children R&D: Formulation Safe biscuit Nourishing biscuit Tasty biscuit Do not use Milk, Egg and Soybean!! Product name Amaranth biscuit Manna biscuit Wheat flour Wheat flour Major ingredients Amaranth powder Skim milk Milk Egg Energy/100g 427 kcal 432 kcal Protein/100g 7.1g 6.5g Amino acid score 28 30 Limiting amino acid Lysine Lysine Cereal Amaranth (Amaranths) is a replacement of milk and egg. Launched in 1993 Ingredient Constituents Raw material Supplier Manufacturer Allergen remark Name Country of origin Name Country of origin name name Wheat flour Wheat flour Japan Wheat Canada, Australia Wheat A Co. A Co. Sugar Sugar Japan Sugar cane Cuba None B Inc.. U Co. Amaranth powder Amaranth powder Japan Amaranth USA None C Co. C Co. Shortening Rapeseed oil Japan Rapeseed USA None Palm oil Malaysia Palm Malaysia None D Co. V Co. Starch Wheat starch Japan Wheat Canada Wheat Potato starch Japan Potato Japan None E Ltd. E Ltd. Molasses Molasses Japan Sugar cane Cuba None F Co. W Inc. Salt Sodium chloride Japan Sea water Japan None G Inc.. X. Ltd Ammonium bicarbonate Japan Ammonium bicarbonate Japan None Baking powder Sodium bicarbonate Japan Sodium bicarbonate Japan None H Co. H Co. Tartaric acid Japan Tartaric acid Japan None without milk derivatives Japan without milk derivatives Japan None s Dextrin Japan Potato Japan None I Ltd. Y Co Gelatin Germany Pork skin Germany Gelatin Vitamins Vitamin B1 Japan Vitamin B1 Japan None Vitamin B2 Japan Vitamin B2 Japan None J Co. Z Co Each ingredient for formulation should be surveyed its constituents. The formulation list should be updated in any change in order to reflect the change to the product label. 11 12
(Buckwheat) Journey of wheat (Soybean, Corn) (Soybean, Corn) According to the guideline of Identity Preserved handing for GMO, the contamination less than 5 % is allowed. Wheat flour is purchased from the wheat-dedicated supplier. 13 Other major ingredients Amaranth powder Amaranth imported from USA was confirmed no soybean contamination through the warehouse, silo or transportation vessel, namely Amaranth is imported via the distinct route from soybean. In addition, the imported Amaranth cereal is confirmed that the factory milling Amaranth did not mill buckwheat. Shortening Shortening is popularly made of soybean oil. Therefore shortening from rapeseed and palm oils are selected, and purchased from a factory that processes only rapeseed and palm oils. Shortening is supplied in 18-L can to prevent the contamination during the transfer through the pipe, storage tank and tank-lorry. Ingredients should be carefully surveyed with respect to food allergen! 14 Food ingredient which should be noted Origin Function Ingredient Protein Whey (protein) Stabilizer Sodium caseinate Casein hydrolyzate Milk Whey hydrolyzate Fining agent Casein Bulking agent Lactose Bacteriostatic agent Lactoferrin Emulsifier Lecithin Egg Enzyme Lysozyme Fining agent Egg white Formulation aid Starch Sweetner Glucose syrup (wheat based) Dextrun Maltodexitrin (what based) Wheat Dough conditioner Gluten (wheat) Malt extract Wheat hydrolyzate Enzyme Carboxypeptidase Enzyme Amylase Protein (Soy) Protein isolate Emulsifier Lecithin Soy bean hydrolyzate Soy bean Enzyme Amylase Antioxidant Tocopherol Babbling agent Saponin Edible oil Soy bean oil Peanuts Edible oil Peanuts oil Buckwheat Antioxidant Rutin Fish Carrier for vitamin and flavor, fining agent Fish gelatin Raw material hardly recognized the origin Education Raw material is not as pure as chemical reagent Formulation, education and monitoring 15 Receiving raw materials On receiving, confirm the purchased raw material agrees to the stipulated quality by the supplier specification. The purchased raw materials are monitored (tested) for food allergen. Case: Undeclared egg in ready-made meal Changing the out-source company, the product formulation was not transferred properly to the new company. Consequently, the final product was found undeclared egg. Case: Undeclared milk in bakery product Margarine of initial formulation did not use any milk, but newly purchased margarine containing Milk in flavor. However, this information was not transferred to the packaging division and the package was not label Milk. As the raw material change is not unusual, keep the consistency of ingredients and product label! 16
Production line (1) Dedicated line: Food allergen management is simple because the line only manufactures the product with same formulation, namely can avoid cross contamination. Limited only for the mass production product One biscuit line costs about US$ 3.5 million. Raw materials are mixed in mixer. Biscuit dough is sliced by the cutter. Sliced dough is conveyed into the oven. The production capacity is; 480,000 package/24hr (= Eat 3 package/day 438 years) 125 production days for 60 million packages (1 Package for 1 Thai citizen) The same taste is easy to be fed up, so the product change in taste, flavor, shape etc. is necessary. (2) Shared line: Biscuit is placed into tray after cooling. Package biscuit Biscuit is now ready to release. 17 18 Cleaning Wash by water: The best method. Some parts of the machinery cannot use water. Wiping with wet or dry clothes: Used instead of water-washing Vacuum cleaning: Dry area. Not to scatter particles. Barely removes firmly-stuck deposits Compressed air: Dry area. Strong enough to remove deposits, Scatters particles Raw materials are mixed in mixer. Biscuit dough is sliced by the cutter. Sliced dough is conveyed into the oven. There are un-washable parts in the production line. The complete cleaning by disassembly after Package biscuit. each production is not realistic. Biscuit is placed into tray after cooling. Biscuit is now ready to release. The factory worker considers that all raw materials are edible and safe. Accordingly, the education about cleaning in terms of food allergen management is important for the worker. 19 20
Monitoring Monitoring method and critical control point ELISA: Quantitative Input raw materials Releasing finished product Lateral-flow (LF): Simple & easy, qualitative Swab sample of the production line Washing and rinse of cleaning Japan has the food allergen regulatory limit,10 ppm, consequently the quantitative production record are required for the government inspection. Monitoring considering processing effect Allergen Food matrix Egg N.D. 92.8 N.D. 47.2 N.D. 46.9 Milk (Casein) 57.8 74.8 14.2 26.1 11.1 72.7 Milk (Beta-lacto globulin) 4.36 82.7 N.D. 30.8 5.33 60.8 Wheat 15.4 96.6 N.D. 20.6 Peanut 87.6 175 22.5 88.7 Buckwheat N.D. 105 54 79.7 Recovery (%) from 10 ppm incurred model processed food. 21 Orange juice Biscuit Strawberry jam Con. Imp. Con. Imp. Con. Imp. 22 Conclusion Food allergen management:1. ücorrect labeling Declare the regulated food allergen correctly on the product label üprevent the cross contamination Prevent un-intentional inclusion of the regulated food allergen ümonitoring Monitor the regulated food allergen at the critical control point Thank you for your kind attention! 23 24