An intensive training course entitled
Skills in Controlling Critical Points in the Halal Industry and its Services.
A prerequisite of Halal Lead Auditor
Halal Critical Points of Animal Source Materials
The Third Gulf Conference on Halal Industry and its Services
13-15 May, 2014Sheraton Hotel, State of Kuwait
Professor Mian N. RiazDirector, Food Protein R&D Center, Graduate Faculty, Nutrition and Food
Science Department, The Texas A&M University System
المكثفة الدورة التدريبية مھارات التحكم بالنقاط الحرجة في صناعة الحالل وخدماته
2104مايو 12النقاط الحرجة الحالل في المواد ذات األصل الحيوانيفندق الشيراتون، دولة الكويت
The Third Gulf Conference on Halal Industry and its Services
13-15 May, 2014Sheraton Hotel, State of Kuwait
ميان محمد نديم رياض. د.أمدير أبحاث البروتين، جامعة تكساس أيه أند أم، تامو، الواليات المتحدة
األمريكية
66 66 Billions slaughtered each yearBillions slaughtered each year Meat Meat pproduction roduction ddoubled from oubled from 1980 1980 to to 2007 2007 from from
136136..7 7 to to 285285..7 7 Million Million ttonsons Pork Pork aaccounts ccounts 4343%,%, Poultry Poultry 2727%%, Beef/Veal , Beef/Veal 2626% %
World Meat Consumption World Meat Consumption
and others and others 44% %
We consume onlyWe consume only 6868% of chicken% of chicken 6262% of pig % of pig 5454% of bovine% of bovine
5252% f h% f h
Sources of Animal Derived MSources of Animal Derived Materialsaterials
5252% of sheep or goat% of sheep or goat
Remaining millions of lbs of meat transformed into Remaining millions of lbs of meat transformed into food, feed, cosmetic, pharmaceutical and technical food, feed, cosmetic, pharmaceutical and technical useuse
Animal Derived Animal Derived IIngredientsngredients
Widely used in food productsWidely used in food products
UnavoidableUnavoidable
Difficult to substituteDifficult to substitute
Lack of legislative guidelinesLack of legislative guidelines Lack of legislative guidelinesLack of legislative guidelines
Masked by unMasked by un--decipherable chemical namesdecipherable chemical names
Dilemma of Halal Dilemma of Halal CConsumersonsumers
Lack of awareness about animal ingredients Lack of awareness about animal ingredients
Understanding Understanding ppackaging ackaging llabelsabels
Complexity of food Complexity of food iingredientsngredients
Ambiguous food Ambiguous food iingredientsngredients
Diversity of pDiversity of productsroducts
Emerging Emerging nnew ew ffood productsood products
Halal Consumers, therefore, rely only on Halal Halal Consumers, therefore, rely only on Halal logoslogos
Dilemma Dilemma of Halal of Halal CConsumersonsumers
Most Commonly Most Commonly Used Used Animal PartsAnimal Parts The The Unusual Uses Unusual Uses for Afor Animal Body Partsnimal Body Parts
Most Commonly Most Commonly Used Used Animal PartsAnimal Parts
Protein Hydrolysate
Pancreatic Enzyme
Bacteria
INS Number: 243,261-1, 261-2, 262-1, 262-2, 263, 271, 280, 281, 282, 283, 296, 297, 300, 301, 302, 304, 317, 322, 326, 327, 330, 331-2, 331-1, 331-3, 332, 332-2, 333, 350-1, 350 2 351 1 351 2 352 1 352 2 363 381Hydrolysate
CultureMedia
Varieties of Raw Materials
Bacteria
350-2, 351-1, 351-2, 352-1, 352-2, 363, 381, 415, 420, 421, 422, 432, 433, 434, 435, 436, 442, 469, 471, 472b,472c, 472f, 472g, 474, 475, 476, 478, 480, 481-2, 481-2, 482-1, 482-2, 491, 492, 493, 494, 495, 570, 575, 576, 578, 579, 585, 620, 621, 622, 623, 627, 631, 634, 635, 636, 639, 951, 1100, 1520
Chemicals
Animal Animal Derived Derived IIngredientsngredients
Gelatin / CollagenGelatin / Collagen EnzymesEnzymes
Known Ingredients Less Known Ingredients
Mono Mono and and DiDi--GlyceridesGlycerides LecithinLecithin Glycerol / GlycerinGlycerol / Glycerin LardLard TallowTallow Rennet & Pepsin / WheyRennet & Pepsin / Whey Natural & Artificial Natural & Artificial FlavorsFlavors
Amino Amino Acids (Acids (LL--Cysteine)Cysteine) Vitamins & MineralsVitamins & Minerals Hydrocolloids & GumsHydrocolloids & Gums Hydrolyzed Vegetable ProteinHydrolyzed Vegetable Protein Casing (for sausage)Casing (for sausage) Blood (media for microbes)Blood (media for microbes) CastoreumCastoreum
GelatinGelatin
Gelatin Gelatin –– Thoroughly Thoroughly Natural Natural and and HealthyHealthy
•• Gelatin Gelatin is a pure natural protein obtained from animal raw is a pure natural protein obtained from animal raw materials containing materials containing collagen collagen
P d d b th ti l h d l i fP d d b th ti l h d l i f llll•• Produced by the partial hydrolysis of Produced by the partial hydrolysis of collagencollagen
•• Gelatin Gelatin is a natural and healthy foodstuff with a long is a natural and healthy foodstuff with a long traditiontradition
•• The The pure protein offers a large number of as yet unbeaten pure protein offers a large number of as yet unbeaten advantages and plays a major role in the modern food advantages and plays a major role in the modern food industryindustry
•• Gelatin Gelatin is worldwide the most used hydrocolloid due to its is worldwide the most used hydrocolloid due to its unique unique propertiesproperties
Gelatin is MultitalentedGelatin is Multitalented
Gelling, Thickening and StabilizingGelling, Thickening and Stabilizing
Gelatin is UniqueGelatin is Unique Great melt in mouth feelGreat melt in mouth feel
Gelatin forms a thermo reversible gelGelatin forms a thermo reversible gel
Best compared withBest compared with “Replacers”“Replacers”
Food ApplicationsFood Applications
ConfectioneryConfectionery
DessertsDesserts
Meat PreparationsMeat Preparations
Health DrinksHealth Drinks
Uses of Uses of GGelatinelatin Flavored milkFlavored milk
YogurtYogurt
Sour creamSour cream
Cottage cheeseCottage cheese
Imitation dairy productsImitation dairy products
Ice creamIce cream
CheesecakesCheesecakes
MarshmallowMarshmallow
ConfectioneryConfectionery
ChocolatesChocolates
Jellied beefJellied beef
Corned beefCorned beef
Fruit juicesFruit juices
CerealsCereals
Puddings etcPuddings etc
Sources of GelatinSources of Gelatin
Bovine BoneBovine Bone
Bovine HideBovine Hide
Pork SkinPork Skin Pork SkinPork Skin
OthersOthers–– Pig BonePig Bone
–– Fish scaleFish scale
Halal Gelatin MarketHalal Gelatin Market1010%% of the gelatin of the gelatin produced in the world is produced in the world is deemed Halal deemed Halal
4343%% of of world world production of gelatin use pig production of gelatin use pig skinskin
2929%% use bovine hidesuse bovine hides2929%% use bovine hides use bovine hides
2525%% source material is from bonessource material is from bones
7070%% of Gelatin is made in western worldof Gelatin is made in western world
Halal Halal GelatinGelatin Must:Must:
Derived from halal sourcesDerived from halal sources
–– BOVINE animalsBOVINE animals
Slaughtered according to Slaughtered according to shariahshariah
From a plant that produces halalFrom a plant that produces halal gelatingelatin onlyonly
How to Get Halal Gelatin?How to Get Halal Gelatin?
From a plant that produces halal From a plant that produces halal gelatingelatin onlyonly
Gelatin Production ProcessGelatin Production Process
Halal Control Halal Control PPoints in Gelatin oints in Gelatin PProductionroduction
Degreasing
Fresh bones Dry bone Cattle hide
Acid treatment
HCP1
HCP3
HCP2
Lime treatment
Extraction, Evaporation,
Extrusion, Drying
Milling and blending
Packaging and labeling
HCP4
HCP5
HCP6
HCP7
Halal Control Halal Control PPoints in Gelatin oints in Gelatin PProductionroduction
HCP1HCP1: : All raw material All raw material (cattle hides, bones) should (cattle hides, bones) should be Halalbe Halal
HCP2HCP2: : Proper degreasing Proper degreasing to avoid cross contaminationto avoid cross contaminationto avoid cross contaminationto avoid cross contamination
HCP3HCP3: : Vats of acid Vats of acid treatment should be treatment should be dedicated for Halal onlydedicated for Halal only
HCP4HCP4: : Lime treatment Lime treatment should also have vats should also have vats dedicated specifically for dedicated specifically for HalalHalal
Halal Control Halal Control PPoints in Gelatin oints in Gelatin PProductionroduction
HCPHCP55: : Extraction, Extraction, evaporation, extrusion, and evaporation, extrusion, and drying must be done in drying must be done in clean equipmentclean equipment
CC HCPHCP66: : Milling and Milling and blending equipment should blending equipment should be cleanbe clean
HCPHCP77: : Must be packed in Must be packed in clean containersclean containers
Basic & Halal SCM From Farm to ForkBasic & Halal SCM From Farm to Fork
Halal Perspective
SuppliersVendors
&Consumers
DemandDriven- Halal
Farm/Livestock
Raw : Halal animals Selection Process
Handling -Slaughtering
Ingredient & Additives
BasicPerspective
ManufacturerSuppliers
Driven- Sales
Revenue-Inventory
Cost-On- Time Delivery
Farm/Livestock
Raw : Halal animals
Handling -Slaughtering
Conformity-Safety and
Health-Product
Info.-Quality-Variety-Animal Welfare
-Convenience
etc
Processing & Unit Operations
-Preliminary Operations-Conversion Operations-Preservation Operation
Handling
Packaging
Warehouse/Storage
Logistics/Transportation
Fork - ConsumptionDistribution
Storage/Outlets
-Cycle Time-Lead Time
-Transportation
Cost-Warehouse
Cost-Supplier
Base-Width/Depth
of Distribution
Ensuring Halalness in Gelatin ChainEnsuring Halalness in Gelatin Chain
Only Halal Animals are slaughteredSlaughtering as per Shariah ( in Islamic way)
Bone Mills
Slaughter House
Community SHs & Abattoirs‘ supply Raw bones
1
2
Shipment certificate for each batch
Gelatin Plant
Customer
Traceability- produce only 100% Halal Gelatin
4
5
Ossein Plant Batch Processing3
Apple sauce Apple sauce ProcessingProcessing
Cold PressCold Press±± EnzymeEnzyme
±± AscorbateAscorbate
Receive FruitReceive FruitDumpDumpWash Wash
Inspect Inspect AnalyzeAnalyze
Disintegrate Disintegrate Chop/ MillChop/ Mill
Gelatin to Facilitate Filtration Gelatin to Facilitate Filtration –– Hidden IngredientHidden Ingredient
Cloudy Juice Cloudy Juice Pack Fresh or Pack Fresh or
PasteurizePasteurize
Hot Fill, Hot Fill, Aseptic Aseptic
Process, Process, Concentrate, Concentrate,
or Freezeor Freeze
Enzyme Enzyme TreatmentTreatment
~~1 1 hr. @ hr. @ 5050C C OrOr
~~88Hrs @ Hrs @ 2020CC
Centrifuge or Centrifuge or Coarse FilterCoarse Filter
Haze Proof Haze Proof GelatinGelatin, ,
BentoniteBentonite, or , or HeatHeat
Fine FilterFine Filter
Enzymes in Halal Food Enzymes in Halal Food PProductionroduction
Enzymes play a vital role as catalysts Enzymes play a vital role as catalysts
Bioengineered enzymes are cheaper to produceBioengineered enzymes are cheaper to produce
The use of microbial enzymes is more The use of microbial enzymes is more tibl ith H l l f d d titibl ith H l l f d d ticompatible with Halal food productioncompatible with Halal food production
However, animalHowever, animal--derived enzymes are still used derived enzymes are still used in the food industryin the food industry
Enzymes Enzymes -- Examples of UsesExamples of Uses
Used in food to improve taste, color and Used in food to improve taste, color and texturetexture
Speed up processSpeed up process
Reduce cost of production Reduce cost of production
Increase yield Increase yield
Improve color and aroma Improve color and aroma
Enzymes in Halal Food Enzymes in Halal Food PProductionroduction
In baking, enzymes help to In baking, enzymes help to improve quality, improve quality, freshness, and shelf life of freshness, and shelf life of baked goodsbaked goodsbaked goodsbaked goods
In cheese making, In cheese making, enzymes help to coagulate enzymes help to coagulate milk and aid the ripening milk and aid the ripening processprocess
Enzymes in Halal Food Enzymes in Halal Food PProductionroduction
In juice industry, enzymes increase yields In juice industry, enzymes increase yields and improve color and aromaand improve color and aroma
Enzymes can be used in the extraction of Enzymes can be used in the extraction of vegetable oilvegetable oilvegetable oilvegetable oil
34
HCPs for a Conventional HCPs for a Conventional PProcess forrocess forExtracting Extracting EEnzymes from Animal organsnzymes from Animal organs
Grinding
Releasing
Halal animal organ HCP1
HCP3HCP2
Release agents
Extraction and purification
Standardization
Packaging, labeling HCP5
HCP4
Ingredients
HCPs for a Conventional HCPs for a Conventional PProcessrocessfor Extracting for Extracting EEnzymes from Animal organsnzymes from Animal organs
HCPHCP11: : Animal must be Halal Animal must be Halal for enzyme extractionfor enzyme extraction
HCPHCP22: Use separate : Use separate equipment for Halal and nonequipment for Halal and non--q pq pHalal productsHalal products
HCPHCP33: : Enzymes might not Enzymes might not be present in the tissues in be present in the tissues in soluble form and may need to soluble form and may need to be released or made soluble be released or made soluble to increase the yield by using to increase the yield by using Halal chemicals onlyHalal chemicals only
HCPs for a Conventional HCPs for a Conventional PProcessrocessfor Extracting for Extracting EEnzymes from Animal organsnzymes from Animal organs
HCPHCP44: : Enzyme strength Enzyme strength can be adjusted using several can be adjusted using several ingredients (including ingredients (including preservatives and preservatives and emulsifiers) that should beemulsifiers) that should beemulsifiers) that should be emulsifiers) that should be suitable for Halal productionsuitable for Halal production
HCPHCP55: : Labeling should be Labeling should be properly marked/documentedproperly marked/documented
Advantages of using EnzymesAdvantages of using Enzymes
FastFast
Reaction is specificReaction is specific
Produce little byproductsProduce little byproducts
Cost Cost ssavingaving
To Label or not to Label To Label or not to Label EEnzymesnzymes
Enzymes are usually used as Enzymes are usually used as processing aid processing aid
In cheese and bakery In cheese and bakery products, enzymes might products, enzymes might remain active in the final remain active in the final productproduct
Mention their sources on the Mention their sources on the labellabel
Some time Animal Some time Animal IIngredients are Hiddenngredients are Hidden
Juice Processing with EnzymesJuice Processing with Enzymes
With With Pulp Pulp -- EnzymesEnzymesto improve juice yieldto improve juice yieldto p o e ju ce y e dto p o e ju ce y e d
Without Pulp Without Pulp -- Enzymes Enzymes For For Clarification Clarification
To To Hydrolyze Colloidal PolysaccharidesHydrolyze Colloidal Polysaccharides
Amino AcidsAmino Acids
Natural sources & synthetic Natural sources & synthetic raw material raw material
NaturalNatural –– Extracts from animal Extracts from animal sourcessources
SyntheticSynthetic –– starting materials of starting materials of plant originsplant origins
Amino AcidsAmino Acids
Questionable amino acidsQuestionable amino acids
LL-- cysteinecysteine
LL-- glutamineglutamineLL-- glutamineglutamine
Monosodium glutamate (Ajinomoto?)Monosodium glutamate (Ajinomoto?)
Use of LUse of L--cystinecystine
In Foods:In Foods:
Used in pizza crust, donuts, batters, breading, breading crumbsUsed in pizza crust, donuts, batters, breading, breading crumbs
Natural SourcesNatural Sources::Natural SourcesNatural Sources::
Derivatives of human hair, animal hair and duck feathersDerivatives of human hair, animal hair and duck feathers
Some time Animal Ingredients are HiddenSome time Animal Ingredients are Hidden
Some time Animal Ingredients are HiddenSome time Animal Ingredients are Hidden
Commonly L-Cysteine is made fromfrom human hair and duck feathers
Some time Animal Ingredients are HiddenSome time Animal Ingredients are Hidden
While artificial cysteine is
available, it is cost prohibitive
and mostly used to createand mostly used to create
halal products
How to Cope with Animal Based Ingredients?How to Cope with Animal Based Ingredients?
InIn--depth analysis of the processdepth analysis of the process
Listing animal, plant and synthetic ingredientsListing animal, plant and synthetic ingredients
Scrutiny of ingredients (specification and halal status)Scrutiny of ingredients (specification and halal status)
Substitute ingredients. For example; fish gelatin & Substitute ingredients. For example; fish gelatin & synthetic Lsynthetic L--cysteine) cysteine) yy y )y )
How to Cope with Animal Based Ingredients?How to Cope with Animal Based Ingredients?
Monitoring all major and minor processing aidsMonitoring all major and minor processing aids
Documentation to assure continuous monitoring Documentation to assure continuous monitoring
Periodic monitoring of the sources of ingredients Periodic monitoring of the sources of ingredients
Surprise audits and frequent auditsSurprise audits and frequent audits
P lid ti i l b t t tP lid ti i l b t t t Process validation using laboratory tests Process validation using laboratory tests