ARBAMINCH UNIVERSITY

SAWLA CAMPUS

INDIVIDUAL ASSIGNMENT

COURSE NAME: FOOD FORTIFICATION

NAME: DAWIT TADESSE

ID: RAMIT/568/11

JANUARY 2023

SAWLA, ETHIOPIA
Table of Contents
FORTIFICATION PROCEDURES................................................................................................3

1.1 Introduction.......................................................................................................................3

1.2 Solid-solid mixing (dry mixing).......................................................................................3

1.2.1 Solid-liquid mixing....................................................................................................4

1.2.2 Liquid-liquid mixing..................................................................................................5

1.2.3 Encapsulation.............................................................................................................5

1.2.4 Cereal grain reconstitution.........................................................................................6

1.3 Point of fortification..........................................................................................................6

1.4 Packaging..........................................................................................................................7

1.5 Packaging materials and containers..................................................................................8

1.6 HACCP and QACCP......................................................................................................10

2 Reference...............................................................................................................................13

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 FORTIFICATION PROCEDURES

1.1 Introduction
Various addition methods have been developed depending on the technologies used in food
processing: dry mixing of cereal products such as powdered milk and beverages; dissolution in
water for liquid milk, beverages, and fruit juices, as well as in water for baking bread, pasta, and
cookies; spraying, as in the case of iodizing corn flakes and salt, where the vitamins do not
support the extrusion or cooking process; for the enrichment of fatty products like margarine,
lipposoluble vitamins are dissolved in oil; adhesion for sugar fortification, in which a vegetable
oil adheres vitamin A crystals in powder form to the surface; coating, as in rice, where the
vitamins sprayed on the grain must be coated to prevent vitamin losses during washing the grain
prior to cooking; and Extrusion as in rice where vitamins are mixed with powdered cereal using
binding agents and extruded into whole cereal grains.

The simplest way to add one or more micronutrients to a food vehicle is to use a mixing
procedure. Even when more sophisticated techniques (e.g., encapsulation or reconstitution of rice
grains fortified with vitamin A) are employed in specific situations and for specific purposes,
mixing will still be required for uniform dispersion in the food vehicle.

Depending on the nature of the mixed components, various types of mixes can be distinguished:
solid-solid, solid-liquid, and liquid-liquid. Most dry foods are fortified using a dry premix.
(Information on procedures/distributors of premixes and fortificants can be obtained from the
Micronutrient Initiative.)

1.2 Solid-solid mixing (dry mixing)

The most popular technique for adding small amounts of micronutrients to dry foods is dry
blending, which can be done in batches, continuously, or a combination of both. The efficiency
of mixing is influenced by the characteristics of the ingredients, including their size, shape,
density, hygroscopicity, and electrostatic properties, as well as their proportions.

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The ingredient properties of all additives should be as similar as possible to ensure homogeneity
during processing, packaging, storage, and distribution as well as uniform mixing and mix
maintenance. The likelihood of segregation increases with the size of the differences.

The choice of mixing equipment depends largely on the requirements of the mixing operation.
Mixer attributes, which can greatly affect the mixing effectiveness, include mechanical energy
input, particle attrition, batch size or size of continuous flow, and mixing time. Mixers are widely
used in the food industry and are available in a variety of designs and configurations to match the
different requirements. The main types of mixers for dry mixing follow.

Batch mixers: In batch systems the micronutrient premix is prepared separately and a specific
quantity is added to each batch. The most common batch mixers are:

Drum mixers: The simplest type of mixers, which consist of a horizontal rotating drum with or
without ribbons.

Screw mixers: a popular mixer is the "Nauta" mixer, a vertical cone mixer, which consists of an
inverted cone fitted with circulating screw agitators.

Ribbon blender: The horizontal ribbon blender consists of a rotating shaft fitted with two
helical ribbons, which rotate in opposite directions inside a semicircular trough

Continuous mixers: for continuous systems, the fortificant is added through a volumetric or
gravimetric solids feeder at a rate compatible with the flow rate of the food vehicle to ensure the
correct dosage in the product.

Commonly used continuous mixers are screw conveyors (often with cut and folded flights and/or
paddles).

1.2.1 Solid-liquid mixing

If the fortificant or premix is in liquid form then the fortificant should be fed to the food vehicle
by spraying, where the fortificant is added in a solution form as an atomized spray.

Spray nozzles are positioned over a belt conveyor or a screw conveyor or inside a rotating drum.
Both the "Nauta" mixer and ribbon blender are used for mixing liquids into solids by mounting
spray nozzles.

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For iodization of salt crystals, drip-feeding, where the fortificant is added in solution form to the
dry salt, is still commonly used, but spray mixing is increasingly preferred (Mannar and Dunn
1995). Figure 4-ic is a schematic elevation of a continuous spray mixing plant for salt iodization.

For small-scale production of fortified foods, simple low-cost mixing equipment can be used.
One can think of hand mixing and the use of a rotary drum unit that works like a cement mixer

1.2.2 Liquid-liquid mixing

The micronutrient is dissolved or dispersed in a liquid vehicle (water or oil) and then mixed or
homogenized into the product for liquid or semi-moist meals. Vertical tanks with turbine or
propeller agitators are used for mixing. The viscosity, flowing properties, and mixability of the
components, as well as the amounts of the components being mixed, all affect how effectively
the components are combined. Antioxidants are included in the premix for micronutrients
including vitamin A, vitamin C, and vitamin B vitamins that are vulnerable to oxidative
destruction. Additionally, it is reduced exposure to oxygen and divalent ions.

1.2.3 Encapsulation
Encapsulation is a process of coating dry, free-flowing powder particles. Depending on the size
of these particles, the technology is referred to as microencapsulation (coating liquids and super-
fine powder particles of 500 microns and under), or macro encapsulation (coating of larger
particles of 5,000 microns and above). Coating powder particles between this range (500 and
5,000 microns) is simply referred to as encapsulation (with no micro or macro prefix added). The
primary objective of encapsulation is to extend shelf life and quality of the product by separating
the fortificant from the vehicle's components and environment until release is desired. Despite a
slow development of the encapsulation technique over the past few years, its application in the
food processing industry is now growing rapidly.

Encapsulation is used to mask undesirable flavors and to isolate reactive components to prevent
the degradation of micronutrients. In multi nutrient fortification, the use of encapsulation will
help to provide barrier protection to separate the micronutrients from one another to avoid
adverse nutrient—nutrient reactions. For encapsulating vitamins, modified food starch or
vegetable fats may be used as a coating agent.

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Encapsulated vitamins offer reduced after-taste and off-flavors; are protected from hygroscopic,
thermal, or oxidative degradation; and have enhanced shelf life, better flow ability, and less
dusting (Duxbury and Swientek 1992). In developing a stable formulation to fortify salt with
both iron and iodine, the University of Toronto has, under a Micronutrient Initiative- funded
study, used a new technique of dextrin microencapsulation to create a barrier between ferrous
fumarate and potassium iodate. Acceptability and bioavailability of the micronutrients using this
formulation are proposed to be studied in a series of trials.

1.2.4 Cereal grain reconstitution

The reconstitution of broken rice grains into whole grains is known as cereal grain reconstitution.
In the manufacturing process, food-grade lard, a small amount of maize oil, and this premix
containing all-trans retinyl palmitate are combined with rice flour made from broken rice grains.
In a new formulation, oils like coconut or peanut oil are used in place of lard. At 1 mg/g of
premix, alpha-tocopherol and ascorbic acid are added. In order to serve the vitamin A-deficient
population, the fortified grains are then transformed into rice grains and mixed with regular rice
at a ratio of 1:100 to 1200. The fortificant is shielded by the proprietary binding agent while
being rinsed and cooked.

1.3 Point of fortification

The procedure for adding micronutrients is typically determined by the fortifier to be used, the
commodity to be fortified, the fortifier system used by the producer, and the processor's
preferences. Although this can result in separation, adding the fortificant after processing, as with
flaked grains, will improve stability profiles. Therefore, the fortificant may occasionally need to
be applied before heat-processing operations, such as in the case of canned goods. the whole
manufacturing process from production to find appropriate and convenient point(s) where
fortification may be integrated with the current system at little additional expense! It is important
to carefully consider importation points to the customer.

One of the most important factors affecting the point-of- addition of a micronutrient or premix is
the stability of the micronutrients. Operations such as cleaning/rinsing, cooking, aeration,
heating, extrusion, or drying, etc., may significantly affect the biological functions and stability
of the added nutrients. Iodine, for example, is subject to vaporization when exposed to excess
heat during processing. Iron compounds are subject to oxidation and color changes. Vitamin A is

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subject to oxidation, hydrolysis, and biochemical reactions that could reduce its potency. The
importance of any of these factors is dependent on time, temperature, oxygen, and composition
of the food. Consequently, it is advisable that certain micronutrients be added to the foods after
unit operations involving heating, aeration, and washing (Lund 1991),

As a general guideline, addition is preferred at that point in the process that will: Provide
sufficient agitation to ensure that the nutrients are uniformly distributed, Present the food at some
fixed, known volume or weight, Provide for ease of addition, and eliminate as many adverse
processing conditions as possible (Parman and Salinard 1963).

For products imported at a single entry point by a single large importer, the point-of-addition
could be at the point-of-entry where the product is invariably repacked. This, however, depends
on cost and available resources. For products imported from one production source by multiple
importers, it is best to specify that the product be fortified at the production source at the
prescribed level. Sometimes, a combination of the foregoing strategies will have to be adopted.

There are pros and cons for locating the fortification plants either at the point-of-manufacture or
close to the consuming areas. If the plant is located at the production point, there is minimum
additional handling involved, but losses in transit and storage are possible. If the fortification
plants are located at the consumption points, losses would be minimized, but multiple handling
and storage might make it uneconomical.

The question also arises as to which agency would own and operate these plants at the
consumption centres and bear the additional handling charges. The consensus is in favour of
locating the plant as close to the point of production as possible and/or just before packing to
maximize retention of the fortificant (Mannar and Dunn 1995). Summarizes the preferable point
of-addition for a number of foods.

1.4 Packaging
The fortified food should be appropriately packed in order to reduce micronutrient losses during
the course of storage. The fortificant used, the kind of packing, the exposure of the package to
the climate at the time of fortification, and the amount of time between fortification and actual
consumption all affect the retention rate of the micronutrient in meals. Packaging plays a
significant role due to the scarcity of packaging materials in many developing nations. Before the

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product is created, a source of suitable packaging materials may occasionally be located (Fellows
and Axtell 1993).

Fortified food-production centers are often far from the consumption areas, therefore, adequate
precautions should be taken to ensure that these foods ultimately reach the consumer with the
recommended level of fortificant. For this reason, shelf life testing is highly recommended.
Hygroscopic products like flour and salt easily attract moisture and become wet when
improperly packaged and transported over long distances under humid conditions. This causes
biochemical and micro- biological deterioration. Efforts should be made to improve the
distribution network to reduce the time between fortification and consumption of foods.

Packaged foods should be marked to identify the contents for monitoring purposes. Ideally, the
package should also be marked with the production date of the content so that the time elapsed
between fortification and consumption can be calculated. All packages should carry expiration
dates to ensure that the product still has the adequate amount of the fortificant. The stipulations
for handling, transportation, storage, and sales of iodized, packaged salt as described in Table 4-2
are also applicable for other fortified foods (Mannar and Dunn 1995).

1.5 Packaging materials and containers

There are two types of packaging materials: rigid containers and flexible packaging. Rigid
containers include glass and plastic bottles, jars, cans, pottery, wood, boxes, drums, tins, plastic
pots, and tubes. They all, to a varying degree, give physical protection to the food inside that is
not provided by flexible packaging. On the one hand, some types of rigid packaging have the
advantage of providing a perfect hermetic seal. On the other hand, although most rigid containers
are strong, they are more expensive than flexible packaging. Glass jars are not suitable as
packaging materials for foods that are adversely affected by light unless the jars are stored in a
dark place or if the fortified food stored in a glass jar stays stable on exposure to light.

Flexible packaging that can be used to make wrappings, sacks, and bags includes plastic films,
papers, foil, some types of vegetable fibres, and cloths.

Packaging options for groups of foods are described by Fellows and Axtell (1993):

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Hygroscopic foods: When packed for the humid tropics, hygroscopic foods such as wheat flour,
maize flour, and salt require a moisture barrier. These foods should be packed in airtight bags or
containers. In many countries, this implies a major switch from conventional packaging
materials, like straw or jute, to the more expensive plastic lined bags and other containers. The
packaging units in the case of bulk packaging should not exceed 50 kg (in accordance with
International Labor Organization (ILO) regulations) to avoid the use of hooks for lifting the
bags. Bags once used for packaging other articles such as fertilizers, cement, chemicals, etc.,
should not be used for packaging fortified foods.

Edible oils and fats: Cooking oils are susceptible to rancidity, therefore, lightproof and airtight
packaging is required. Metal cans, glass, and possibly plastic bottles are the most suitable
containers.

Dairy products: Microbial contamination is the major problem in using dairy products as a
vehicle for fortification.

Packaging should be sterilized to prevent contamination after processing. During distribution and
storage the products should be kept cool and away from direct sunlight.

Polyethylene bags are adequate if the product is carried home and consumed right away. For
long-term storage of cheese, polyethylene should not be used because of migration of chemicals
from the plastic into the fatty food. For distribution purposes, reusable glass bottles with foil lids
are used as a relatively low-cost package, for milk.

Bread: Because of its short shelf life, packaging bread is mainly used to keep these products
clean and is usually not used as a barrier to moisture or air. Clean paper is an adequate packaging
material. If polyethylene film is used, condensing on the inside of the bag should be prevented by
allowing the baked goods to cool down after baking and before packaging.

Biscuits: When packed for the humid tropics, dry biscuits require a moisture barrier and
packaging to resist mechanical damage.

For biscuits with a high fat content a lightproof/airtight packaging to avoid rancidity is also
required. Cardboard cartons coated with polypropylene or cellulose film is applicable. The use of
polyethylene should be discouraged because of the migration of chemicals from the plastic into

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the fats contained in the biscuits, in dry areas, the foregoing constraints are not of importance. In
these areas, the packaging is simply used as a way to store the food and to keep it clean.

Beverages Fruit juices, which are intended for immediate consumption after opening, rely on
pasteurization for their preservation. The packaging is used to prevent recontamination by
microorganisms. Glass jars, cardboard cartons coated with polypropylene or cellulose film, or
coated metal tins are applicable.

Cereals/flour: Like hygroscopic foods, these also require a moisture barrier and should be
packed in airtight bags or containers.

Peanut butter: Although peanut butter is yet to become popular in developing countries, it can
be a good source of protein and micronutrients. Peanut butter is susceptible to rancidity because
of the high oil content. The packaging used must be Light proof and airtight. Metal cans and
glass bottles are the most suitable containers.

1.6 HACCP and QACCP

All food production activities must be monitored and controlled within the framework of an
effective QA program. The addition of nutrients to a food for the purpose of fortification adds to
the control points which have to be considered. Poor manufacturing control leading to
excessively high levels of nutrients in the finished product could have important health
implications for the consumer if intake of the nutrient reaches the toxic dose. Conversely, low
levels of nutrients in the finished product could render it nutritionally ineffective. This could also
have serious health implications if the target population in the fortification program was at high
nutritional risk. Poor manufacturing control could also lead to other quality defects related to
interactions of added nutrients with other components of the system.

The following steps in the implementation of a quality assurance program in the production of a
fortified food have been outlined by Wilson (1991):

i. Product specifications - All specifications for fortificants, food vehicle and any other
ingredients must be documented as well as acceptable deviations of these. These include
specification of particle size, color, potency, and level of fortification as well as any other
requirement which might be deemed necessary.

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 ii. Product safety assessment - This involves an assessment of microbiological, chemical
and physical hazards for all ingredients and the finished product
iii. Product analysis - Sampling and testing procedures for all ingredients and the finished
product must be explicitly stated.
iv. Determination of critical and quality control points - Based on firsthand knowledge of the
total process (including the plant facility, equipment and environment) stages at which
inadequate control could lead to unacceptable health risk or adversely affect product
quality are identified. The system of controls and actions to be taken at each control point
are documented.
v. Recall system - A mechanism must be put in place whereby product can be recalled if
such action becomes necessary.
vi. QA audit - Periodic checks are necessary to verify that the QA system is effective and
product quality is maintained up to the ultimate consumer.
vii. Feedback mechanism - Response to consumers and other relevant groups to correct any
deficiencies discovered.
viii. Documentation of QA system - Details of the QA program used in the production of the
fortified food must be readily available to relevant individuals and organizations.
Shortcomings of many fortification programs in the past have been due to failure to establish an
adequate quality assurance program. Evaluation of the fortification of sugar with vitamin A in
Guatemala showed that only 30% of samples tested were fortified at levels within the legal limits
(Nestle, 1993). A study of iodine content in iodized salt samples obtained from several plants in
India also provided an example of the need for greater control in processing.

In the determination of critical and other control points for any process accurate flow diagrams
outlining the total process have been used. The construction of an accurate flow diagram for any
given process requires firsthand knowledge of the processing facility and its environs so that all
factors which might be expected to impact on product safety could be identified. Annex 1
includes a list of common critical control points and examples of monitoring procedures in the
processing of selected fortified foods, which are intended to demonstrate the main points of a
quality assurance program.

I. Use of HACCP serves to improve food safety control and should be applied on that basis;

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 II. The elaboration of food safety policies by government and international agencies should
use risk analysis as the basis for establishing food safety priorities and for focusing
inspection resources. These policies should be implemented through national strategic
plans;
In the post Uruguay Round of GATT, the Codex Alimentarius Commission should recognize the
importance of its role in harmonizing and establishing food standards, guidelines and
recommendations particularly as it relates to safety of food in international trade. Codex should
develop a strategic plan which will include a strengthening of the scientific basis for risk
analysis, equivalence and the elaboration of its standards, guidelines and other recommendations
and should include specific instructions to the Codex Committees on incorporating HACCP.

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 2 Reference
Fellows, P.; Axtell, B. 1993. Appropriate food packaging. International Labour Organization
(ILOITOOL), Geneva, Switzerland.

Lund, D.B. 1991. Engineering aspects of nutrifying foods. In Bauemfeind, iC.; Lachance, P.A.,
ed., Nutrient additions to food: Nutritional, technological and regulatory aspects. Food
and Nutrition Press, pp. 473—494.

Parman, G.K.; Salinard, G.i. 1963. Vitamins as ingredients in food processing. In Joslyn, M.A.;
Heid, iL., ed., Food processing operations, Vol. II. AVINan Nostrand Reinhold, New
York, NY, USA.

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