wine industry haccp
TRANSCRIPT
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IMPLEMENTATION OF HAZARD ANALYSIS CRITICALCONTROL POINT (HACCP) SYSTEM TO THE ALCOHOLICBEVERAGES INDUSTRYL K Kourtis a amp I S Arvanitoyannis Dr PhD ba Department of Agriculture Crop and Animal Production Pedion Areos University ofThessaly School of Technological Sciences Volos 38334 Greece (Hellas)b Department of Agriculture Crop and Animal Production Pedion Areos University ofThessaly School of Technological Sciences Volos 38334 Greece (Hellas)
Available online 06 Feb 2007
To cite this article L K Kourtis amp I S Arvanitoyannis Dr PhD (2001) IMPLEMENTATION OF HAZARD ANALYSIS CRITICALCONTROL POINT (HACCP) SYSTEM TO THE ALCOHOLIC BEVERAGES INDUSTRY Food Reviews International 171 1-44
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FOOD REVIEWS INTERNATIONAL 17(1) 1ndash44 (2001)
IMPLEMENTATION OF HAZARD ANALYSISCRITICAL CONTROL POINT (HACCP) SYSTEMTO THE ALCOHOLIC BEVERAGES INDUSTRY
L K Kourtis and I S Arvanitoyannislowast
University of Thessaly School of Technological Sciences Departmentof Agriculture Crop and Animal Production Pedion Areos 38334
Volos Greece (Hellas)
ABSTRACT
Alcoholic beverages (fermented or not) have been consumed for morethan three thousand years and generally they have been considered safe becauseof their alcohol content However in recent years adulteration (ie use of low-cost inappropriate alcohol) has made rapid progress in this field Food and drinkcontrol and safety can be assured within the frame of strict adherence to qualityand safety systems (ISO 9000 series HACCP and TQM) The flow diagrams forthe production of several alcohol drinks were shown and an extensive hazardanalysis critical control point (HACCP) analysis was carried out in order toreveal the weaknesses of the production line and to suggest the critical limitsin compliance with legislation and the corresponding preventive and correctivemeasures
Key Words HACCP Alcoholic beverages Hazard CCP Ouzo Gin VodkaBrandy Distilled spirits Wine Sake Beer
INTRODUCTION
It has taken almost 30 years (since 1971 when it was officially presented forthe first time) for the concept of Hazard Analysis Critical Control Point (HACCP) tobecome universally accepted as one of the most rigorous preventive programs whosestrict implementation can assure food safety (12) Although HACCP is a system
lowastAddress correspondence to I S Arvanitoyannis Dr PhD E-mail parmenion33hotmailcom
1
Copyright Ccopy 2001 by Marcel Dekker Inc wwwdekkercom
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2 KOURTIS AND ARVANITOYANNIS
aiming at zero defect products it is well known that this is not feasible and thereal target is the minimization of unacceptable unsafe products When a companydecides to adopt HACCP it should be able to set controls at each point of theproduction line at which safety problems (physical chemical and microbiological)are likely to occur (3)
Prior to initiating a HACCP system a company must endeavor to put togethera HACCP plan most often described by the five following steps (1345) a) identifyHACCP resources and assemble the team b) describe the food and its distributionmethod c) state clearly intended use and consumers and d) develop a process flowdiagram and e) verify the validity of this diagram in practice (operation)
The regulatory requirements for Sanitation Standard Operating Procedures(SSOPs) in conjunction with Good Manufacturing Practices (GMPs) should alsobe considered as a prerequisite to HACCP The following seven HACCP principlesconstituting the major steps to writing an HACCP (637)
1 Conduct a hazard analysis2 Identify critical control points (CCPs) by applying the HACCP decision
tree (8 Fig 1)3 Establish critical limits (CLs) for each CCP4 Establish monitoring actions5 Establish corrective actions6 Establish record-keeping procedures7 Establish verification procedures
Today HACCP is continuously gaining importance and worldwide acceptabil-ity being implemented by most countries all over the world The implementation ofHACCP in the EU in particular was introduced by the Council Directives 914393and 92592 HACCPrsquos implementation is considerably facilitated when other com-plementary quality assurance systems (ISO 90012) are already in place (9) Thecurrent tendency is integrating HACCP and ISO 9001 or ISO 9002 (1011) withinthe frame of Total Quality Management
Since the two most important stages for the drink industry are fermentationand bottling where hazards are likely to occur special care is required (trainedpersonnel sanitation equipment maintenance GMP)
This review article aims to present an overview of HACCP implementation toalcoholic beverages through the production and distribution chains and to pinpointthe current CCPs CLs and preventive and corrective actions due to be undertakenin case any deviations are observed
BEER
Introduction
Beer is an alcoholic beverage produced by the fermentation of wort obtainedfrom barley malt flavored with hops The alcoholic content of beer ranges from 4
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 3
Figure 1 HACCP decision tree (102)
for ordinary beer up to 15 Beerrsquos first production in Mesopotamia by the Sume-rians in the 5th millennium BC classifies it among the most ancient of alcoholicbeverages Towards the middle of the 3rd millennium BC there is documentary evi-dence of beer drinking by the Egyptians who probably introduced beer technology
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4 KOURTIS AND ARVANITOYANNIS
in Europe Beer drinking in northern Europe dates back to early antiquity contraryto the Mediterranean countries in which wine was the commonest drink A criticalpoint in its history was the works of Louis Pasteur which greatly contributed to theunderstanding of beer production (12)
Beer Main Production Stages
The main stages for beer production are shown schematically in Figure 2together with their critical control point (CCP) numbers
Incoming Raw Materials (CCP1)
The principal raw materials used to brew beer are water malted barley hopsand yeast Barley is required to be of sufficiently good malting quality in order togerminate and to produce a satisfactory product yield Other factors such as dor-mancy and losses during malting have also to be considered (13) The malting orsubsequent brewing characteristics are subtly affected by the weather conditionsprevailing over the growing period Some information regarding the quality of abatch of barley can be obtained by visual inspection but usually it is complementedby analyses including moisture content total nitrogen 1000-grain weight and theportion of nongerminating grain The National Institute of Agricultural Botany(UK) provides descriptions of the European malting varieties Residues of certainpesticides used on malting barley survive through to the final malt and wort and canaffect the process and quality of the end product (CCP) Fungicides and herbicidesinfluencing enzyme synthesis during malting process can accumulate in the yeastthereby affecting the next fermentation (14) The critical limits of these substancesare prescribed by Codex Alimentarius and are presented in Table 1 Presence ofheavy metals above the specifications of Directive 80776EC and mycotoxin pro-duction more than 004 mgL mainly from Fusarium species such as aflatoxinsochratoxine A zearoleon deoxyniralenol constitutes a high risk for human health(CCP) (15) Temperature and relative humidity are two interacting parameters thatdefine the germination of spores of different microorganisms (16) Visual inspec-tion and biological plate methods detect the fungal contamination for mycotoxinanalysis employment of HPLC or ELISA is required (17)
The quality of the water used is a major factor affecting the beer quality(CCP) The development of strict water control standards was introduced by mostbreweries in which water is filtered through activated carbon as well as ion ex-change resins to remove impurities (pesticides herbicides and industrial wastes)Two ions of particular importance in water are calcium and carbonatebicarbonatewhich control the pH during brewing Calcium also protects α-amylase from heatdestruction thereby permitting liquefaction of starch during mashing (18)
Hops not only provide bitter flavor to the beer but impart a hoppy characteras well These aroma components are derived from the essential oil The brewing
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 5
Figure 2 Process flow diagram of beer production (2226)
value of hops depends on the resin fraction which amounts to 15 and the essentialoil comprising sim05 Total resin is defined as the material soluble in both coldmethanol and diethyl ether ldquosoftrdquo resin is that proportion of the total which issoluble in hexane comprising mainly α and β-acids while ldquohardrdquo resin is insolublein hexane The α-acids that are the most significant bittering precursors can bedistinguished from other soft resins from their ability to form a lead salt which isinsoluble in methanol The determination of moisture and seed content also provideuseful conclusions about their quality (13) Adjuncts of carbohydrate origin other
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6 KOURTIS AND ARVANITOYANNIS
Tabl
e1
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rB
eer
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Mon
itori
ngC
orre
ctiv
eR
espo
nsib
lePr
oces
sSt
ep(P
MC
)aM
easu
res
CC
PPa
ram
eter
Cri
tical
Lim
itPr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
fung
ide
velo
pmen
tte
mpe
ratu
rean
dR
Hre
gula
tion
duri
ngst
orag
e
Myc
otox
inpr
oduc
tion
000
4m
gL
Vis
uali
nspe
ctio
nof
fung
ide
velo
pmen
tH
PLC
EL
ISA
E
PSan
alys
is
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
er
Cer
tified
supp
liers
sc
hedu
lein
spec
tions
Pres
ence
ofE
nter
o-ba
cter
iace
ae
0M
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Cha
nge
supp
lier
Stri
cktly
follo
win
gin
stru
ctio
nsC
onta
min
atio
nof
mic
robi
alpr
epar
atio
ns
100
clea
nC
hang
epr
epar
atio
nm
etho
dC
Effi
cien
tdis
ease
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
barl
eyh
ops
wat
er
By
pest
icid
eas
desc
ribe
dby
Cod
ex
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erC
ertifi
edsu
pplie
rsPr
oper
wat
erde
cont
amin
atio
nH
eavy
met
als
pres
ence
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Rej
ectio
nof
spec
ific
batc
hD
e-m
etal
lisat
ion
step
Use
ofde
ioni
ser
Wat
errsquos
elec
tric
alco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nise
r
Aut
omat
icdi
scon
tinua
tion
ofde
ioni
ser
anal
ysis
ofw
ater
sam
ples
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 7
Mal
ting
(CC
P2)
CU
seof
indi
rect
heat
ing
syst
ems
cont
roll
ow-N
Ox
burn
ers
ND
MA
prod
uctio
ndu
ring
kiln
ing
25
ppb
Con
tinuo
usch
ecki
ngth
ear
eas
peci
fican
alys
es
Rej
ectio
nor
mix
ing
with
othe
rba
tche
s
Qua
lity
cont
rol
man
ager
PC
ontr
olof
time
tem
pera
ture
and
RH
Col
our
and
flavo
urde
velo
pmen
tSp
ecifi
edby
part
icul
arpl
ant
Con
tinuo
usm
onito
ring
ofpr
oces
sing
cond
ition
s
Mix
ing
with
othe
rm
alts
rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
MPr
oper
hadl
ing
oper
atio
nsaf
ter
prod
uctio
n
Myc
otox
inpr
oduc
tion
000
4m
gL
Vis
uali
nspe
ctio
nof
fung
ide
velo
pmen
tH
PLC
EL
ISA
E
PSan
alys
is
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
er
Mas
hing
(CC
P3)
CC
ontr
olof
tem
pera
ture
CIP
ND
MA
prod
uctio
nde
terg
ent
resi
dues
25
ppb
Non
eC
ontin
uous
reco
rdin
gof
the
proc
essi
ng
Adj
ustl
aute
ring
prog
ram
Qua
lity
cont
rol
man
ager
Lau
teri
ng(C
CP4
)C
Sche
dule
Insp
ectio
nun
der
plat
ecl
eani
ng
AT
NC
lt20
ppb
Mic
robi
olog
ical
and
chem
ical
anal
yses
Prop
erm
aint
ain
re-l
aute
ring
ofth
eba
tch
Qua
lity
cont
rol
man
ager
Boi
ling
(CC
P5)
CC
orre
ctus
eof
boile
rtr
eatm
ent
chem
ical
s
Con
tam
inat
ion
with
dete
rgen
ts0
CIP
syst
emR
epai
rC
IPb
atch
reje
ctio
nQ
ualit
yco
ntro
lm
anag
erFe
rmen
tatio
n(C
CP6
)M
Aer
atio
nof
wor
tus
eof
yeas
tfor
max
6ge
nera
tions
Poor
yeas
tvi
abili
tyldquo
stuc
krdquofe
rmen
tatio
n
Min
90
viab
leye
astc
ell
Yea
stco
ncen
trat
ion
ferm
enta
bilit
yO
2co
ncen
trat
ion
inth
ew
ort
Incr
ease
prop
agat
ion
freq
uenc
yw
ort
aera
tion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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8 KOURTIS AND ARVANITOYANNIS
Tabl
e1
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Mon
itori
ngC
orre
ctiv
eR
espo
nsib
lePr
oces
sSt
ep(P
MC
)aM
easu
res
CC
PPa
ram
eter
Cri
tical
Lim
itPr
oced
ures
Act
ions
Pers
onne
l
Ferm
enta
tion
(CC
P6)
MIn
spec
tion
ofC
IPsy
stem
and
equi
pmen
t
Lac
toba
cill
iac
etic
acid
bact
eria
and
wil
dye
asts
Pres
ence
in1
mL
plat
e+1
mL
actid
ione
Plat
eco
unt
met
hod
ora
rapi
dde
tect
ion
met
hod
Prop
erdi
sinf
ectio
nof
equi
pmen
tre
proc
essi
ngof
the
batc
h
Qua
lity
cont
rol
man
ager
Filtr
atio
n(C
CP7
)C
Use
CO
2
prefi
lling
offil
ter
with
wat
er
O2
upta
kegt
02
ppm
diss
olve
dO
2
Mea
sure
men
tof
diss
olve
dO
2
Surv
eyof
filtr
atio
nfo
rin
crea
sed
O2
pick
up
Qua
lity
cont
rol
man
ager
Bot
tlec
anin
spec
tor
(CC
P8)
CG
MP
Cle
anin
gpe
rfor
man
ceN
oso
lids
noliq
uid
rem
nant
sE
labo
rate
elec
tron
icre
cogn
ition
syst
ems
afte
rC
IP
Rew
ashi
ngof
bottl
esC
IPsy
stem
insp
ectio
n
Qua
lity
cont
rol
man
ager
PC
ertifi
edsu
pplie
rpr
oper
hand
ling
ofbo
ttles
Bot
tles
prop
erfo
rfo
ods
and
drin
ks
bottl
esco
nditi
on
Cra
cks
scra
tche
sab
senc
eO
n-lin
evi
sual
cont
rol
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlec
anfil
ler
(CC
P9)
CIn
stal
latio
nof
cont
rolli
ngeq
uipm
ento
nth
eC
IPsy
stem
Con
tam
inat
ion
with
dete
rgen
tsC
ompl
ete
abse
nce
Org
anol
eptic
exam
inat
ion
offil
led
bottl
es
Bat
chre
ject
ion
Tra
ined
pers
onne
l
Bot
tlec
anse
aler
(CC
P10)
PC
orre
ctin
stal
latio
nof
equi
pmen
tB
low
-off
effe
ctO
ccur
renc
ere
duce
dto
anac
cept
able
leve
l
Con
trol
sets
ealin
gpr
essu
reA
utom
atic
rem
oval
ofde
stro
yed
bottl
es
Tra
ined
pers
onne
l
Bot
tlec
anpa
steu
riza
tion
(CC
P11)
PR
unni
ngpa
steu
rise
rac
cord
ing
topr
ogra
m
Oxi
datio
nca
used
ofw
rong
tem
pera
ture
-tim
ese
t
Max
65 C
for
20m
inq
uick
cool
ing
atth
eex
it
Con
tinuo
uson
-lin
etim
e-te
mpe
ratu
rech
ecki
ng
Adj
ust
tem
pera
ture
m
aint
ain
equi
pmen
t
Tech
nica
lm
anag
er
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 9
Bot
tlec
anin
spec
tion
(CC
P12)
PR
egul
arin
spec
tion
ofth
em
achi
nery
Phys
ical
dam
age
Occ
urre
nce
redu
ced
toan
acce
ptab
lele
vel
On-
line
mon
itori
ngE
quip
men
tst
anda
rdis
atio
nTe
chni
cal
man
ager
Lab
elin
g(C
CP1
3)P
Car
eful
sele
ctio
nof
the
etiq
uette
sM
ispl
aced
etiq
uette
sR
educ
edto
anac
cept
able
leve
lV
isua
lche
cks
cont
rolo
fth
eeq
uipm
ent
Rel
abel
ing
the
spec
ific
batc
hT
rain
edpe
rson
nel
Bot
tlec
anpa
ckag
ing
(CC
P14)
PC
orre
ctin
stal
latio
nof
the
equi
pmen
tB
ottle
sco
nditi
ondu
ring
palle
tisat
ion
Abs
ence
ofri
fts
inth
elu
tec
rack
orsc
ratc
hes
On-
line
visu
alco
ntro
lA
djus
tthe
equi
pmen
tpa
ram
eter
s(s
peed
pre
ssur
e)
Tech
nica
lm
anag
er
Stor
age
(CC
P15)
PC
ontr
olst
orag
eco
nditi
ons
Org
anol
eptic
cond
ition
ofbe
erSp
ecifi
edby
the
part
icul
arpl
ant
Sche
dule
dco
ntro
lsof
finis
hed
prod
uct
Adj
ustt
hest
oreh
ouse
cond
ition
s
Tra
ined
pers
onne
l
aP
MC
stan
dfo
rph
ysic
alm
icro
biol
ogic
alan
dch
emic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
10 KOURTIS AND ARVANITOYANNIS
than malt are sometimes used as an additional source of extract to supplementmalt Unmalted cereal adjuncts usually contain no active enzymes and thereforerely on malt or exogenous enzymes to provide the necessary enzymes for starchconversion (19)
Yeast growth cannot be separated from the fermentation process and it isnecessary to the production of both beer and fresh yeast for use in subsequentfermentations The quality control of yeasts comprises a) the selection maintenanceand supply of a suitable strain and b) the routine assessment of purity and detectionof microbial contamination (CCP) (20)
Malting (CCP2)
This process involves steeping the barley in a shallow bed of water at a tem-perature of 10ndash15C so that its moisture content amounts to 45 wt- of barleyBarley is then allowed to germinate under controlled temperature conditions atapproximately 15C and RH100 with constant turning to prevent matting therootlets The barleycorn undergoes germination through air passage via the germi-nating malt for 3ndash5 days Gentle heating stops germination due to moisture removaland promotes formation of flavor compounds The kiln temperature regime is cru-cial for the color of malt and the survival of enzymes to be used in the mashingprocess Kilning duration usually varies between 24 and 48 h Time temperatureand moisture content are varied to control color and flavor development Chemicalmicrobiological and physical hazards may be encountered in this step In partic-ular nitrosodimethylamine (NDMA) production during kilning (reaction of NOx
with organic materials) constitutes a chemical hazard with a critical limit (CL) at25 ppb because of its suspected carcinogenic effect In addition mycotoxin pro-duction more than 0004 mgL and color and flavor alteration represent chemicaland physical hazards respectively The NDMA content in malt can be controlled byusing indirect heating systems or by carefully maintained and controlled low-NOx
burners Regular checks should nevertheless be carried out by the maltster so thatthe residual risk caused by polluted air is kept as low as possible (17) The finishedmalt has its rootlets removed and is screened to produce the uniform quality Duringthe malting process two important changes occur a) the barley develops its ownenzyme systems and b) the naturally produced enzymes start to break down the cellstructure of the endosperm (19) Malt quality control tests include hot water extractcolor soluble nitrogen total nitrogen moisture enzyme activities viscosity andlautering prediction tests The microbiological status of malt used in the followingsteps (CCP) is very much dependent on its handling operations after production (16)
Milling
The main function of dry or wet milling is to reduce the malt particle sizeto form grist (ground or milled grain) The particle size reduction facilitates the
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 11
extraction of soluble components mainly sugars and nitrogenous compounds fromthe endosperm (21)
Mashing (CCP3)
Mashing the first step in wort production involves extracting soluble materi-als from the milled malt This is accomplished by feeding the grist through Steelrsquosmasher a hydrator consisting of a large-bore tube bent at right angles During itspassage through the vertical portion of tube the grist is spayed with hot water (typ-ically 65C) and then mixed with the help of a revolving screw (22) The floatingendosperm particles hydrate and undergo further amylolytic scission by α- andβ-amylases Processors adjust the pH and temperature conditions to allow bothenzymes with a range of susceptibility to pH and temperature to work effectivelyNDMA production (CL = 25 ppb) as well as possible detergent residues constitutepotential chemical hazards for public health Continuous monitoring at the process-ing and adjustment of the lautering program and Cleaning In Place (CIP) systemwhen deviation occurs are proper preventive and corrective actions respectively
Lautering (CCP4)
The lauter tun is a vessel normally rinsed thoroughly with a sparging or hotwater delivery system before receiving the mash which precipitates at the flat floorof slotted stainless steel or brass plates At tun center there is a lautering machineon the shaft of which rotating rakes are attached to facilitate draining the wortinto a collection vessel called grant The wort is recirculated through the lauter tununtil it reaches a certain degree of clarity whereupon it is delivered to the kettle(21) In lautering production of Apparent Total N-nitroso compounds (ATNC)above the CL of 20 ppb constitute a CCP that should be monitored with chemicaland microbiological analyses Scheduled inspection and under-plate cleaning canprevent insufficient separation of trub from wort (23)
Boiling (CCP5)
Wort is boiled for up to 2 h at atmospheric pressure following the additionof hops (CCP) The shape of copper boiling time and temperature can affect thequality of produced beer The major objectives of wort boiling are a) wort steril-ization and enzyme inactivation b) extraction of bitter and other substances fromhops and formation of flavor compounds and c) evaporation of excess water andwort concentration evaporation of undesirable flavour volatiles Wort contamina-tion of the wort with Enterobacteriaceae from hops can result in various off-flavorsincluding ldquovegetablerdquo and ldquophenolicrdquo taints (24) Correct use of boiler treatmentchemicals steam condensate tasting for carrying over the taints and operation of
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12 KOURTIS AND ARVANITOYANNIS
phenol analyses are all essential to avoid chemical contamination and taints devel-opment (23)
Clarification
Wort clarification is conducted either through sedimentation or filtrationWhen whole hop cones are used it is necessary to employ either a hop back ora hop separatorndashfilter The drop in hop usage and the widespread acceptance ofpreisomerized extracts led to utilization of a vertical cylinder known as whirlpoolwhich induces sustainable circulation of the trub collecting as a compact cone in thebase Whirlpools are more suited to larger worts and can also be used with ale Inmodern breweries centrifuges constitute a promising alternative to whirlpools (25)
Cooling
To prepare for fermentation the clear hopped wort is cooled usually in aplate heat exchanger During cooling it is advisable to aerate or even to oxygenatethe wort because next processing step involves yeast growth promoted in the pres-ence of dissolved oxygen despite the low dissolved oxygen concentration in wort(7ndash14 ppm) (22)
Fermentation (CCP6)
Fermentation aims at producing ethanol by fermenting yeasts Yeasts vary intheir behavior during fermentation some strains tend to flocculate trap plug CO2 andrising to the top whereas others do not flocculate and precipitate Several lagers areproduced by bottom fermentation while many types of ales and stouts are producedby top fermentation Saccharomyces cerevisiae is usually the top fermenting yeastin the range of 18ndash22C whilst the bottom-fermenting are strains of Saccharomycesuvarum that function in the range of 7ndash15C (26) Therefore the temperature atwhich fermentation occurs is very crucial for the further stages of beer productionThe modern use of cylindroconical vessels has reduced the fermentation periodfor ales and lagers from 7 to 2 or 3 days and from 10 to 7 days respectively (27)Fermentation is monitored by taking samples for measuring the specific gravityand can be controlled by varying the cooling rate (20) ldquoStuckrdquo fermentation wherethe required ethanol level is not attained and microbial contamination with Lacticacid bacteria mainly Lactobacilii and Pediococcus which cause taints duringmaturation or in bottle storage (28) represent microbiological hazards which arethe only hazard detected at this stage Common causes for ldquostuckrdquo fermentationinclude premature yeast flocculation and yeast failure to metabolize maltotriosedue to repression by glucose (25) A minimum of 90 viable yeast cells (CL) canbe applied to ensure the development of the process During fermentation the pH
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 13
drops from 52 to 42 and by its completion the yeast is removed either as a top orbottom crop and retained to pitch the next fermentation Apart from the conventionalmicrobial detection methods with plate count several rapid detection methodspotentially applied in breweries such as ATP bioluminescence flow cytometryand polymerase chain reaction have been developed to reduce the incubation timefrom 3ndash4 days to 1ndash2 (2930)
Maturation
Maturation includes all those changes occurring between the end of primaryfermentation to beer filtration (31) Ale is matured at relatively warm temperatures12ndash20C while lagers are held under much cooler conditions The warmer temper-atures allow the rapid metabolism of any residual and priming sugars as well asloss of green flavors within 1ndash2 weeks depending on beer type yeast strain wortcomposition and primary fermentation conditions In case of lager the beer used tobe held at refrigerated temperatures for up to several months after fermentation al-lowing formation of proteintannin complexes (18) Today the enzyme addition hassubstantially shortened this process to several weeks during which flavor maturesEnzymes such as papain may be added during transfer between fermentation andmaturation tank The dosage of the proteolytic enzyme varies depending on typeof beer and process Enzyme activity decreases progressively during maturationuntil its inactivation with pasteurization Part of the enzyme absorbed in the yeastsurface is removed during filtration (19)
Filtration (CCP7)
Beer produced during fermentation is turbid and should be clarified prior to itsmarketing This turbidity is due to the presence of yeasts and proteinaceous materi-als associated with carbohydrates and polyphenols The formation of these proteinprecipitates is attributed to cold temperature low pH and poor solubility in alcoholicsolutions (32) To prevent this from occurring in the final product the beer may besubjected to various chill-proofing treatments during its storage These treatmentsgenerally include the addition of clays to absorb the colloidal materials or prote-olytic enzymes used to further solubilize the protein fraction (33) Since oxygenuptake during this process could severely affect the product organoleptic charac-teristics a CCP of dissolved oxygen should be applied with a CL of 02 ppm (34)
Packaging and Sealing
The packing section comprises several CCPs including the containers to beused their cleaning and disinfection (CCP8) the filler line (CCP9) and the sealer(CCP10) The bursting pressure of the bottles as guaranteed by the manufacturerin his specifications for the new glass may no longer be valid in case of reusable
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14 KOURTIS AND ARVANITOYANNIS
bottles due to the considerable physical stress during already exerted upon themduring the filling process Insufficient cleaning of reusable bottles due to low temper-atures and concentrations of the employed cleaning solutions as well as presence ofextraneous entrapped materials within bottles and improper emptying consist pos-sible hazards Moreover cleaning solution remnants and shards introduced throughthe procedure pose problems under working conditions The beer filler may be con-taminated by cleaning and disinfection solutions Contamination sources may bedue to inadequate pressure or faulty CIP system resulting in cleaning and disinfect-ing solution remains in the pressure tank or the ring bowl of the filler (3536) Thecrown corker should be correctly installed the filling pressure of bottle caps on themouths of the bottles should be adjusted to ensure a specified blow-off effect toavoid bottle bursting After filling there should be a full bottle inspector detectingglass particles in bottles or possible leakage (37)
Bottle Pasteurization (CCP11)
Pasteurization is carried out to ensure the beer shelf life over a period ofmonths This is accomplished by the development of tunnel pasteurization in whichthe beer bottle is subjected to 60C for 20 min Over-pasteurization which causesoxidation and can adversely affect beer flavor (38) is a potential physical hazardFurthermore it is crucial to check the time-temperature procedure with adequatecorrective actions for assuring the production of a satisfactory product
Bottle Inspection (CCP12)
Bottle inspection after the pasteurization step is important to ensure that bottleshave not been damaged during the process (39) Should such a situation occur theequipment has to be standardized by the production engineer
Labeling and Standardization (CCP13)
Labeling of the package should comply with the requirements of the CodexGeneral for the labeling of prepackaged foods (40) This means that the name of theproduct shall be clearly declared there must be a list of ingredients in descendingorder of proportion no other fruit may be represented pictorially except those usedand ldquothe date of minimum durabilityrdquo will be declared by the month and year inuncoded numerical sequence
BottleCan Packaging (CCP14)
Bottles (cans) are packaged into paperboard boxes of various sizes accordingto the bottle or can dimensions The encountered hazards can be of physical natureconcerning the bottles (cans) condition during the procedure
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 15
Storage (CCP15)
The finished beer undergoes chemical microbiological and organoleptic anal-ysis to ensure that its properties are within its specification range A synoptical pre-sentation of the occurring hazards CCPs CLs and preventive corrective measuresis given in Table 1
SAKE
Introduction
Sake is a fermented liquor made from rice and coming in many varietiesdepending on the raw materials manufacturing process and process after brewing(41) According to the earliest records sake was originally brewed from rice thathad been chewed to reach saccharification followed by natural fermentation Sakebrewed this way was used as a sacred wine in the worship of the Shinto gods Thisassociation with religion Shintoism and Buddhism has caused a deep intertwiningof sake with the traditions and social customs of Japan Thus today sake is servedat ceremonies and celebrations of all kinds (42) Sake has the highest alcoholpercentage by volume of any fermented beverage In its natural undiluted state itmay contain a potent 20 ethanol compared to 3ndash5 for beer or 9ndash12 for winewhich may reach higher values for fortified wines (4344) The central brewersrsquounion divides sake into four basic flavor types on four axes of sweet sour bitterand umai The latter is another translatorrsquos nightmare which generally ends uptranslated as delicious According to position established along these axes sakeis considered to be of ldquomature typerdquo ldquofragrant typerdquo ldquolight and smooth typerdquo orldquofull-bodied typerdquo (Fig 3) However no set of criteria can adequately express themultiplicity of sensations that together create the flavor unique to any individualsake but there is a perceived need for terms which quickly and simply give thegeneral idea
Figure 3 Main flavor types for sake characterization (43)
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16 KOURTIS AND ARVANITOYANNIS
Sake Main Production Stages
The main stages for sake production are schematically presented in Figure 4
Raw Materials (CCP1)
The main ingredients of Japanese sake are rice sake rice sake yeastand water The rice most suitable for sake should consist of large grains and shouldbe soft with a white part at its center due to coarse cell structure Rice should complywith the maximum residue limits for pesticides and insecticides established by theCodex Alimentarius Commission for this commodity (45) (CCP chemical hazard)For Japanese sake yellow koji mold (Aspergillus oryzae) is used Sake yeast (Sac-charomyces cerevisiae) is a microbe converting the occurring glucose and mineralsin rice and water into alcohol Employment of bubble-free type yeast eliminates
Figure 4 Process flow diagram of sake production (264647)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 17
the bubble removal step thus shortening the brewing period and reducing the costShould the factory wish to employ a specific yeast an adequate disinfection ofthe building interior is required otherwise undesirable bacteria may be introducedwhich could prove hazardous to human health (CCP microbiological hazard) (46)
Rice Polishing (CCP2)
The brown rice used for sake production must be first polished to remove theouter portion of the grain which contains fats proteins minerals and amino acidsthat can cause unpleasant flavors leaving the starch residues that are located in thecenter of the grain Nowadays machines are programmed to automatically removewhatever portion of the rice is required for the specific sake (47) The rice polishingratio (73ndash35) is expressed by the following formula (43)
Rice polishing ratio=(weight of white riceweight of brown rice)times100 (1)
The polishing process should be gently carried out because friction results inheat generation thereby greatly affecting water absorption and rice grain structureBroken grains are unlikely to satisfactorily ferment (47) Maybe the most importantstage in sake production consists of yeast starter mash production which can takeplace either with the classical Kimoto or slightly revised Yamahai process or withthe new ldquohigh speedrdquo methods (48)
Washing (CCP3)
After the rice has been polished rice powder clinging to the grain surface isremoved by washing Washing can be carried out either mechanically or manually(laborious hand washing) and should result in removing most of the organic andinorganic impurities reaching the CLs set by Codex Alimentarius of 15 and01 mm respectively
Soaking (Steeping)
Soaking allows rice to absorb the desired amount of water that is crucial toestablishing the rice consistency For sake produced ldquoen masserdquo simply dumpinginto a vat overnight for as long as 14 h is a usual case (47) However high polishedrice may be soaked within minutes In such a case an error of a minute might proveto have dire consequences for the end product (43)
Steaming (CCP4)
Steaming aims at softening the rice grains and breaking down the starchmolecules thus encouraging the growth of Aspergillus oryzae and eliminating all
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18 KOURTIS AND ARVANITOYANNIS
other microorganisms leaving an initially sterile environment prone to sake moldpropagation Presence of lactic acid bacteria (LAB) and yeasts may occur at theend of this step representing a microbiological hazard and resulting in consider-able organoleptic losses The time can vary from 20 to 60 min depending on thebrewer and apparatus employed (40ndash60 and 20 min for traditional and automatedrespectively) (4346)
Cooling
The ensuing division of steamed rice is mainly related to its further use Apart of it is directly cooled by air blower whereas 20ndash30 is transferred to a heatedculture room to be infected with bacteria spores (Aspergillus oryzae) for sake moldproduction
Koji
Since rice grains contain no sugar it is the action of koji mold that converts thestarch in the grains to sugar The steamed rice is first cooled to 15ndash36C before beingtransferred to the koji culture room (30C) Spores of the mold are sprinkled likefine dust on the rice when it has cooled down to 33C After the spores are kneadedinto the steamed rice the rice is heaped and wrapped in cloths to prevent heat andmoisture loss which are two crucial factors for satisfactory bacterial growth Tomaintain uniform temperature and moisture rice is spread and mixed twice the firsttime after 20 hours (upon the appearance of white flecks) and then 7ndash8 h thereafteraccompanied by a distinctive aroma release (48)
Main Mash (Moromi) and Fermentation (CCP5)
In fermentation the occurring chemical hazards are related to heavy metalspresence (As lt 02 Cd lt 001 Pb lt 03 mgL) pesticide residues (as mentionedin Codex Alimentarius) and residues of detergents (absence) and ethylene glycole(absence) Their CLs can be determined and monitored with specific chemicalanalyses The ingredients of main mash (water koji rice and steamed rice) areadded to the starter mash in three steps (moving from small to bigger recipient)over a period of 4 days at successively lower temperatures thus preventing thegrowth of airborne bacteria (Table 2) A day after the addition of all the ingredientsformation of a moist surface showing clear cracks occurs Furthermore the mashbegins to bubble (indication of fermentation progress) as gas is given off during theburgeoning fermentation The fermentation can take place at various temperaturesand its duration depends on it that is at lower temperatures it takes up to twoweeks but the sake aroma is much more appealing compared to that formed athigher temperatures The characteristic sake aroma results from combined flavor
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 19
Table 2 Quantities of Ingredients at Each Stage of Mixing the Main Mash (Moromi)
Yeast 1st 2nd 3rd 4thStarter (Moto) Addition Addition Addition Additiona Total
Total rice (kg) 210 470 850 1470 3000Steamed rice (kg) 140 330 650 1230 2350Koji rice (kg) 70 140 200 240 65030 Brewerrsquos 1200 1200
alcohol (L)Water (L) 230 420 1010 2030 360 405
aTraditional brewers mix the final mash in three stages The fourth addition of alcohol and wateris a controversial postwar development (Kondo 1984)
components of a number of compounds produced during fermentation (49) Theelevated alcohol content of the fermented sake is related to lipid metabolism ofyeast in the presence of proteolipid provided by the koji molds (5051)
Additions (CCP6)
The addition of alcohol at this stage is carried out unless it is clearly statedthat sake does not contain any alcohol from extraneous sources The added alcoholshould not contain methanol or if it does the content of the latter should be lessthan 05 gL because of its toxicity (CCP chemical hazard)
Pressing
Automatic machine presses (consisting of a series of panels with balloon-likesacks attached) are most widely used nowadays instead of the traditional time-consuming method using long bags The remained caked lees are employed forpickle production and cooking or sedimentation of rice particles may occur Alter-natively sedimentation of rice particles at the bottom of the tank may take place
Filtration
Coloring and aging (maturation) inhibition can be effected by using activatedcharcoal filters
Pasteurization (CCP7 and CCP8)
Heating sake preferably twice at 65C kills off the remaining yeast stops en-zyme action and deactivates the lactic acid bacteria that will eventually spoil sakeThis process represents a microbiological hazard for which the specific plant may
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ORDER REPRINTS
20 KOURTIS AND ARVANITOYANNIS
set CLs However in recent years refrigerated storage and transport have madeunpasteurized sake with characteristic aroma available to the consumer (43)
Dilution
The produced sake in its raw state (Genchu) contains more than 20 alcoholby volume but it is generally diluted to about 15ndash16 vol-
BottlingStorageDistribution
The applied procedures are similar to those mentioned for the beer productionA summary of the occurring hazards CCPs CLs and preventive and correc-
tive measures is given in Table 3
WINE
Introduction
Wines are made from the fruit of Vitis vinifera of which there are a greatnumber of varieties growing in many parts of the world The history of wine isinextricably interwoven with human history It might be as true to say that it waswith wine that civilization began for the vine takes longer to mature than any othercrop and does not produce grapes for wine making until its fourth year It is notexactly known when men first had wine but it was accepted as a gift from the godsthe Egyptians attributed it to Osiris and the Greeks to Dionysos Mesopotamia andthe Caucasian slopes were no doubt early sources of wine from where it was spreadto Egypt and Greece and then to the rest of the world (52)
Wine Main Production Stages
The main stages for wine production are schematically presented in Figure 5
Harvesting (CCP1)
Grape harvesting is a CCP comprising both physical and chemical hazardsPhysically the grapes should be sound without rotten parts otherwise oxidativeand microbial contamination can rapidly develop Therefore harvesting shouldbe conducted with the greatest possible care and an efficient disease managementsystem should be applied (5354) Pesticides play an important role in pest man-agement but they should be handled with care because they constitute chemicalhazards (55) At the time of harvest the grapes must have also reached the correctmaturity when Brix and Total Acidity (TA) levels indicate maturity of wine Sincepesticide and fungicide residues on the surface of the berries constitute chemical
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 21
hazards Oliva et al (56) proposed a rapid and simple gas chromatographic methodfor their determination The maximum residue limits for pesticides in grapes andwines are provided by Codex Alimentarius (45) and Organisation International duVin (57) Finally the bulk bins used for grapes transportation should be effectivelydecontaminated to avoid any microbial infection
Stemming
Stemming includes the removal of stem leaves and grape stalks before crush-ing This procedure has several advantages because the total volume of processedproduct drops by 30 thus resulting in smaller tanks and eventually increasingthe productrsquos alcoholic content (58) However the end of fermentation and the al-cohol content of finished product depend mostly on the Brix level of initial grapesStemmers usually contain a perforated cylinder allowing berries to pass throughbut prevent the passage of stems stalks and leaves
Crushing
Crushing typically immediately follows stemming since some crushing ofthe fruit occurs during stemming The released juice is highly susceptible to oxida-tive browning and microbial contamination The most common crushing processesinvolve pressing the fruit against a perforated wall or passing the fruit through a setof rollers It is very important to avoid crushing the seeds to preclude contaminat-ing the must with seed oils the oxidation of which could produce rancid odors andconstitute an undesirable source of bitter tannins Equally important is the properhandling of product because inappropriate timing might lead to a sudden startof alcoholic fermentation and consequently to higher fermentation temperatureswhile a delay might cause microbial contamination and oxidative browning (59)
Maceration
Maceration is the breakdown of grape solids after crushing of grapes Whilemaceration is always involved in the initial stage of red wine fermentation the long-standing trend has been to limit maceration in white wine production Temperatureand duration of maceration depend on grape and wine variety Usually for white androse wines the maceration time is less than 24 h red destined for early consumptionis macerated for 3ndash5 days and red for aging is macerated from 5 days to 3 weeksFermentation usually occurs during this or at the end of maceration The amount ofthe antimicrobial to be used usually added to white musts that are most sensitive tooxidation depends on the crop health and maceration temperature Sulfur dioxidehas a distinct advantage over other antimicrobial agents because of the relativeinsensitivity of the wine yeasts to its action However it is also toxic or inhibitoryto most bacteria and yeasts (ie Candida Pichia Hansenula) at low concentrations(60) and has a rather low retention capability after the clarification step (61)
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ORDER REPRINTS
22 KOURTIS AND ARVANITOYANNISTa
ble
3Su
mm
ary
ofH
azar
dsC
CPs
CL
sM
onito
ring
Cor
rect
ive
Act
ions
and
Pers
onne
lRes
pons
ible
for
Sake
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
a(M
CP
)bM
easu
res
CC
PPa
ram
eter
(CL
s)Pr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
CC
ertifi
edsu
pplie
rs
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
wat
er
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Cer
tified
supp
liers
Hea
vym
etal
spr
esen
cein
wat
er
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Eva
luat
ion
ofth
ede
cont
amin
atin
gm
etho
ds
MC
ertifi
edsu
pplie
rs
prop
erpr
epar
atio
n
Mic
robi
alco
ntam
inat
ion
ofth
ecu
lture
100
clea
nM
icro
biol
ogic
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alys
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ejec
tion
ofsp
ecifi
cba
tch
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Wat
erm
icro
biol
ogic
alqu
ality
Abs
ence
ofpa
thog
ens
Insp
ectio
nof
the
equi
pmen
t
Ric
epo
lishi
ng(C
CP2
)C
Cer
tified
supp
lier
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
polis
hed
rice
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Was
hing
(CC
P3)
PC
ertifi
edsu
pplie
rs
inst
alla
tion
ofau
tom
atic
sepa
rato
r
Ani
mal
impu
ritie
sO
ther
orga
nic
and
inor
gani
cm
ater
01
mm
15
mm
01
mm
Spec
ific
exam
inat
ion
Rew
ashi
ngof
spec
ific
batc
hch
ange
supp
lier
Qua
lity
cont
rol
man
ager
Stea
min
g(f
orun
past
euri
sed
sake
)(C
CP4
)
MG
MP
sche
dule
dm
icro
biol
ogic
alco
ntro
ls
Pres
ence
ofye
asts
and
LA
B
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Spec
ific
batc
hre
proc
essi
ng
CIP
stan
dar-
disa
tion
Qua
lity
cont
rol
man
ager
T
rain
ned
pers
onne
l
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nloa
ded
by [
Sule
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 23
Ferm
enta
tion
(CC
P5)
CM
ater
ialc
ontr
ol
GM
Pco
rros
ion
chec
ks
Hea
vym
etal
pres
ence
Pest
icid
ere
sidu
es
Aslt
02
Cd
lt
001
Pb
lt
03
(mg
L)
Spec
ific
chem
ical
anal
ysis
Dem
etal
lisat
ion
Cha
nge
supp
lier
Rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
GM
Pus
eof
nont
oxic
glyc
ole
Res
idue
sof
ehty
lene
glyc
ole
ampde
terg
ents
0Sp
ecifi
cch
emic
alan
alys
isD
ilutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Alc
ohol
addi
tion
(CC
P6)
CC
ertifi
edsu
pplie
rM
etha
nolc
onte
ntlt
05
gL
GC
exam
inat
ion
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erPa
steu
riza
tion
(CC
P7amp
CC
P8)
MR
unni
ngof
past
euri
ser
acco
rdin
gto
prog
ram
Det
ectio
nof
yeas
tsL
AB
en
zym
atic
activ
ity
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Tem
pera
ture
adju
stm
ent
batc
hre
proc
essi
ng
prop
erm
achi
nery
disi
nfec
tion
Qua
lity
cont
rol
man
ager
Tech
nica
lm
anag
er
aR
egar
ding
the
proc
edur
esof
bottl
ing
stor
age
and
dist
ribu
tion
the
CC
Psar
esi
mila
rto
thos
em
entio
ned
inTa
ble
1fo
rbe
erpr
oduc
tion
bM
CP
stan
dfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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ORDER REPRINTS
26 KOURTIS AND ARVANITOYANNIS
Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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ORDER REPRINTS
28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
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yman
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irel
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
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ded
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yman
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irel
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ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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irel
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itesi
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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FOOD REVIEWS INTERNATIONAL 17(1) 1ndash44 (2001)
IMPLEMENTATION OF HAZARD ANALYSISCRITICAL CONTROL POINT (HACCP) SYSTEMTO THE ALCOHOLIC BEVERAGES INDUSTRY
L K Kourtis and I S Arvanitoyannislowast
University of Thessaly School of Technological Sciences Departmentof Agriculture Crop and Animal Production Pedion Areos 38334
Volos Greece (Hellas)
ABSTRACT
Alcoholic beverages (fermented or not) have been consumed for morethan three thousand years and generally they have been considered safe becauseof their alcohol content However in recent years adulteration (ie use of low-cost inappropriate alcohol) has made rapid progress in this field Food and drinkcontrol and safety can be assured within the frame of strict adherence to qualityand safety systems (ISO 9000 series HACCP and TQM) The flow diagrams forthe production of several alcohol drinks were shown and an extensive hazardanalysis critical control point (HACCP) analysis was carried out in order toreveal the weaknesses of the production line and to suggest the critical limitsin compliance with legislation and the corresponding preventive and correctivemeasures
Key Words HACCP Alcoholic beverages Hazard CCP Ouzo Gin VodkaBrandy Distilled spirits Wine Sake Beer
INTRODUCTION
It has taken almost 30 years (since 1971 when it was officially presented forthe first time) for the concept of Hazard Analysis Critical Control Point (HACCP) tobecome universally accepted as one of the most rigorous preventive programs whosestrict implementation can assure food safety (12) Although HACCP is a system
lowastAddress correspondence to I S Arvanitoyannis Dr PhD E-mail parmenion33hotmailcom
1
Copyright Ccopy 2001 by Marcel Dekker Inc wwwdekkercom
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2 KOURTIS AND ARVANITOYANNIS
aiming at zero defect products it is well known that this is not feasible and thereal target is the minimization of unacceptable unsafe products When a companydecides to adopt HACCP it should be able to set controls at each point of theproduction line at which safety problems (physical chemical and microbiological)are likely to occur (3)
Prior to initiating a HACCP system a company must endeavor to put togethera HACCP plan most often described by the five following steps (1345) a) identifyHACCP resources and assemble the team b) describe the food and its distributionmethod c) state clearly intended use and consumers and d) develop a process flowdiagram and e) verify the validity of this diagram in practice (operation)
The regulatory requirements for Sanitation Standard Operating Procedures(SSOPs) in conjunction with Good Manufacturing Practices (GMPs) should alsobe considered as a prerequisite to HACCP The following seven HACCP principlesconstituting the major steps to writing an HACCP (637)
1 Conduct a hazard analysis2 Identify critical control points (CCPs) by applying the HACCP decision
tree (8 Fig 1)3 Establish critical limits (CLs) for each CCP4 Establish monitoring actions5 Establish corrective actions6 Establish record-keeping procedures7 Establish verification procedures
Today HACCP is continuously gaining importance and worldwide acceptabil-ity being implemented by most countries all over the world The implementation ofHACCP in the EU in particular was introduced by the Council Directives 914393and 92592 HACCPrsquos implementation is considerably facilitated when other com-plementary quality assurance systems (ISO 90012) are already in place (9) Thecurrent tendency is integrating HACCP and ISO 9001 or ISO 9002 (1011) withinthe frame of Total Quality Management
Since the two most important stages for the drink industry are fermentationand bottling where hazards are likely to occur special care is required (trainedpersonnel sanitation equipment maintenance GMP)
This review article aims to present an overview of HACCP implementation toalcoholic beverages through the production and distribution chains and to pinpointthe current CCPs CLs and preventive and corrective actions due to be undertakenin case any deviations are observed
BEER
Introduction
Beer is an alcoholic beverage produced by the fermentation of wort obtainedfrom barley malt flavored with hops The alcoholic content of beer ranges from 4
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 3
Figure 1 HACCP decision tree (102)
for ordinary beer up to 15 Beerrsquos first production in Mesopotamia by the Sume-rians in the 5th millennium BC classifies it among the most ancient of alcoholicbeverages Towards the middle of the 3rd millennium BC there is documentary evi-dence of beer drinking by the Egyptians who probably introduced beer technology
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ORDER REPRINTS
4 KOURTIS AND ARVANITOYANNIS
in Europe Beer drinking in northern Europe dates back to early antiquity contraryto the Mediterranean countries in which wine was the commonest drink A criticalpoint in its history was the works of Louis Pasteur which greatly contributed to theunderstanding of beer production (12)
Beer Main Production Stages
The main stages for beer production are shown schematically in Figure 2together with their critical control point (CCP) numbers
Incoming Raw Materials (CCP1)
The principal raw materials used to brew beer are water malted barley hopsand yeast Barley is required to be of sufficiently good malting quality in order togerminate and to produce a satisfactory product yield Other factors such as dor-mancy and losses during malting have also to be considered (13) The malting orsubsequent brewing characteristics are subtly affected by the weather conditionsprevailing over the growing period Some information regarding the quality of abatch of barley can be obtained by visual inspection but usually it is complementedby analyses including moisture content total nitrogen 1000-grain weight and theportion of nongerminating grain The National Institute of Agricultural Botany(UK) provides descriptions of the European malting varieties Residues of certainpesticides used on malting barley survive through to the final malt and wort and canaffect the process and quality of the end product (CCP) Fungicides and herbicidesinfluencing enzyme synthesis during malting process can accumulate in the yeastthereby affecting the next fermentation (14) The critical limits of these substancesare prescribed by Codex Alimentarius and are presented in Table 1 Presence ofheavy metals above the specifications of Directive 80776EC and mycotoxin pro-duction more than 004 mgL mainly from Fusarium species such as aflatoxinsochratoxine A zearoleon deoxyniralenol constitutes a high risk for human health(CCP) (15) Temperature and relative humidity are two interacting parameters thatdefine the germination of spores of different microorganisms (16) Visual inspec-tion and biological plate methods detect the fungal contamination for mycotoxinanalysis employment of HPLC or ELISA is required (17)
The quality of the water used is a major factor affecting the beer quality(CCP) The development of strict water control standards was introduced by mostbreweries in which water is filtered through activated carbon as well as ion ex-change resins to remove impurities (pesticides herbicides and industrial wastes)Two ions of particular importance in water are calcium and carbonatebicarbonatewhich control the pH during brewing Calcium also protects α-amylase from heatdestruction thereby permitting liquefaction of starch during mashing (18)
Hops not only provide bitter flavor to the beer but impart a hoppy characteras well These aroma components are derived from the essential oil The brewing
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 5
Figure 2 Process flow diagram of beer production (2226)
value of hops depends on the resin fraction which amounts to 15 and the essentialoil comprising sim05 Total resin is defined as the material soluble in both coldmethanol and diethyl ether ldquosoftrdquo resin is that proportion of the total which issoluble in hexane comprising mainly α and β-acids while ldquohardrdquo resin is insolublein hexane The α-acids that are the most significant bittering precursors can bedistinguished from other soft resins from their ability to form a lead salt which isinsoluble in methanol The determination of moisture and seed content also provideuseful conclusions about their quality (13) Adjuncts of carbohydrate origin other
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ORDER REPRINTS
6 KOURTIS AND ARVANITOYANNIS
Tabl
e1
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rB
eer
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Mon
itori
ngC
orre
ctiv
eR
espo
nsib
lePr
oces
sSt
ep(P
MC
)aM
easu
res
CC
PPa
ram
eter
Cri
tical
Lim
itPr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
fung
ide
velo
pmen
tte
mpe
ratu
rean
dR
Hre
gula
tion
duri
ngst
orag
e
Myc
otox
inpr
oduc
tion
000
4m
gL
Vis
uali
nspe
ctio
nof
fung
ide
velo
pmen
tH
PLC
EL
ISA
E
PSan
alys
is
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
er
Cer
tified
supp
liers
sc
hedu
lein
spec
tions
Pres
ence
ofE
nter
o-ba
cter
iace
ae
0M
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Cha
nge
supp
lier
Stri
cktly
follo
win
gin
stru
ctio
nsC
onta
min
atio
nof
mic
robi
alpr
epar
atio
ns
100
clea
nC
hang
epr
epar
atio
nm
etho
dC
Effi
cien
tdis
ease
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
barl
eyh
ops
wat
er
By
pest
icid
eas
desc
ribe
dby
Cod
ex
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erC
ertifi
edsu
pplie
rsPr
oper
wat
erde
cont
amin
atio
nH
eavy
met
als
pres
ence
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Rej
ectio
nof
spec
ific
batc
hD
e-m
etal
lisat
ion
step
Use
ofde
ioni
ser
Wat
errsquos
elec
tric
alco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nise
r
Aut
omat
icdi
scon
tinua
tion
ofde
ioni
ser
anal
ysis
ofw
ater
sam
ples
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 7
Mal
ting
(CC
P2)
CU
seof
indi
rect
heat
ing
syst
ems
cont
roll
ow-N
Ox
burn
ers
ND
MA
prod
uctio
ndu
ring
kiln
ing
25
ppb
Con
tinuo
usch
ecki
ngth
ear
eas
peci
fican
alys
es
Rej
ectio
nor
mix
ing
with
othe
rba
tche
s
Qua
lity
cont
rol
man
ager
PC
ontr
olof
time
tem
pera
ture
and
RH
Col
our
and
flavo
urde
velo
pmen
tSp
ecifi
edby
part
icul
arpl
ant
Con
tinuo
usm
onito
ring
ofpr
oces
sing
cond
ition
s
Mix
ing
with
othe
rm
alts
rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
MPr
oper
hadl
ing
oper
atio
nsaf
ter
prod
uctio
n
Myc
otox
inpr
oduc
tion
000
4m
gL
Vis
uali
nspe
ctio
nof
fung
ide
velo
pmen
tH
PLC
EL
ISA
E
PSan
alys
is
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
er
Mas
hing
(CC
P3)
CC
ontr
olof
tem
pera
ture
CIP
ND
MA
prod
uctio
nde
terg
ent
resi
dues
25
ppb
Non
eC
ontin
uous
reco
rdin
gof
the
proc
essi
ng
Adj
ustl
aute
ring
prog
ram
Qua
lity
cont
rol
man
ager
Lau
teri
ng(C
CP4
)C
Sche
dule
Insp
ectio
nun
der
plat
ecl
eani
ng
AT
NC
lt20
ppb
Mic
robi
olog
ical
and
chem
ical
anal
yses
Prop
erm
aint
ain
re-l
aute
ring
ofth
eba
tch
Qua
lity
cont
rol
man
ager
Boi
ling
(CC
P5)
CC
orre
ctus
eof
boile
rtr
eatm
ent
chem
ical
s
Con
tam
inat
ion
with
dete
rgen
ts0
CIP
syst
emR
epai
rC
IPb
atch
reje
ctio
nQ
ualit
yco
ntro
lm
anag
erFe
rmen
tatio
n(C
CP6
)M
Aer
atio
nof
wor
tus
eof
yeas
tfor
max
6ge
nera
tions
Poor
yeas
tvi
abili
tyldquo
stuc
krdquofe
rmen
tatio
n
Min
90
viab
leye
astc
ell
Yea
stco
ncen
trat
ion
ferm
enta
bilit
yO
2co
ncen
trat
ion
inth
ew
ort
Incr
ease
prop
agat
ion
freq
uenc
yw
ort
aera
tion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
8 KOURTIS AND ARVANITOYANNIS
Tabl
e1
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Mon
itori
ngC
orre
ctiv
eR
espo
nsib
lePr
oces
sSt
ep(P
MC
)aM
easu
res
CC
PPa
ram
eter
Cri
tical
Lim
itPr
oced
ures
Act
ions
Pers
onne
l
Ferm
enta
tion
(CC
P6)
MIn
spec
tion
ofC
IPsy
stem
and
equi
pmen
t
Lac
toba
cill
iac
etic
acid
bact
eria
and
wil
dye
asts
Pres
ence
in1
mL
plat
e+1
mL
actid
ione
Plat
eco
unt
met
hod
ora
rapi
dde
tect
ion
met
hod
Prop
erdi
sinf
ectio
nof
equi
pmen
tre
proc
essi
ngof
the
batc
h
Qua
lity
cont
rol
man
ager
Filtr
atio
n(C
CP7
)C
Use
CO
2
prefi
lling
offil
ter
with
wat
er
O2
upta
kegt
02
ppm
diss
olve
dO
2
Mea
sure
men
tof
diss
olve
dO
2
Surv
eyof
filtr
atio
nfo
rin
crea
sed
O2
pick
up
Qua
lity
cont
rol
man
ager
Bot
tlec
anin
spec
tor
(CC
P8)
CG
MP
Cle
anin
gpe
rfor
man
ceN
oso
lids
noliq
uid
rem
nant
sE
labo
rate
elec
tron
icre
cogn
ition
syst
ems
afte
rC
IP
Rew
ashi
ngof
bottl
esC
IPsy
stem
insp
ectio
n
Qua
lity
cont
rol
man
ager
PC
ertifi
edsu
pplie
rpr
oper
hand
ling
ofbo
ttles
Bot
tles
prop
erfo
rfo
ods
and
drin
ks
bottl
esco
nditi
on
Cra
cks
scra
tche
sab
senc
eO
n-lin
evi
sual
cont
rol
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlec
anfil
ler
(CC
P9)
CIn
stal
latio
nof
cont
rolli
ngeq
uipm
ento
nth
eC
IPsy
stem
Con
tam
inat
ion
with
dete
rgen
tsC
ompl
ete
abse
nce
Org
anol
eptic
exam
inat
ion
offil
led
bottl
es
Bat
chre
ject
ion
Tra
ined
pers
onne
l
Bot
tlec
anse
aler
(CC
P10)
PC
orre
ctin
stal
latio
nof
equi
pmen
tB
low
-off
effe
ctO
ccur
renc
ere
duce
dto
anac
cept
able
leve
l
Con
trol
sets
ealin
gpr
essu
reA
utom
atic
rem
oval
ofde
stro
yed
bottl
es
Tra
ined
pers
onne
l
Bot
tlec
anpa
steu
riza
tion
(CC
P11)
PR
unni
ngpa
steu
rise
rac
cord
ing
topr
ogra
m
Oxi
datio
nca
used
ofw
rong
tem
pera
ture
-tim
ese
t
Max
65 C
for
20m
inq
uick
cool
ing
atth
eex
it
Con
tinuo
uson
-lin
etim
e-te
mpe
ratu
rech
ecki
ng
Adj
ust
tem
pera
ture
m
aint
ain
equi
pmen
t
Tech
nica
lm
anag
er
Dow
nloa
ded
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 9
Bot
tlec
anin
spec
tion
(CC
P12)
PR
egul
arin
spec
tion
ofth
em
achi
nery
Phys
ical
dam
age
Occ
urre
nce
redu
ced
toan
acce
ptab
lele
vel
On-
line
mon
itori
ngE
quip
men
tst
anda
rdis
atio
nTe
chni
cal
man
ager
Lab
elin
g(C
CP1
3)P
Car
eful
sele
ctio
nof
the
etiq
uette
sM
ispl
aced
etiq
uette
sR
educ
edto
anac
cept
able
leve
lV
isua
lche
cks
cont
rolo
fth
eeq
uipm
ent
Rel
abel
ing
the
spec
ific
batc
hT
rain
edpe
rson
nel
Bot
tlec
anpa
ckag
ing
(CC
P14)
PC
orre
ctin
stal
latio
nof
the
equi
pmen
tB
ottle
sco
nditi
ondu
ring
palle
tisat
ion
Abs
ence
ofri
fts
inth
elu
tec
rack
orsc
ratc
hes
On-
line
visu
alco
ntro
lA
djus
tthe
equi
pmen
tpa
ram
eter
s(s
peed
pre
ssur
e)
Tech
nica
lm
anag
er
Stor
age
(CC
P15)
PC
ontr
olst
orag
eco
nditi
ons
Org
anol
eptic
cond
ition
ofbe
erSp
ecifi
edby
the
part
icul
arpl
ant
Sche
dule
dco
ntro
lsof
finis
hed
prod
uct
Adj
ustt
hest
oreh
ouse
cond
ition
s
Tra
ined
pers
onne
l
aP
MC
stan
dfo
rph
ysic
alm
icro
biol
ogic
alan
dch
emic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
10 KOURTIS AND ARVANITOYANNIS
than malt are sometimes used as an additional source of extract to supplementmalt Unmalted cereal adjuncts usually contain no active enzymes and thereforerely on malt or exogenous enzymes to provide the necessary enzymes for starchconversion (19)
Yeast growth cannot be separated from the fermentation process and it isnecessary to the production of both beer and fresh yeast for use in subsequentfermentations The quality control of yeasts comprises a) the selection maintenanceand supply of a suitable strain and b) the routine assessment of purity and detectionof microbial contamination (CCP) (20)
Malting (CCP2)
This process involves steeping the barley in a shallow bed of water at a tem-perature of 10ndash15C so that its moisture content amounts to 45 wt- of barleyBarley is then allowed to germinate under controlled temperature conditions atapproximately 15C and RH100 with constant turning to prevent matting therootlets The barleycorn undergoes germination through air passage via the germi-nating malt for 3ndash5 days Gentle heating stops germination due to moisture removaland promotes formation of flavor compounds The kiln temperature regime is cru-cial for the color of malt and the survival of enzymes to be used in the mashingprocess Kilning duration usually varies between 24 and 48 h Time temperatureand moisture content are varied to control color and flavor development Chemicalmicrobiological and physical hazards may be encountered in this step In partic-ular nitrosodimethylamine (NDMA) production during kilning (reaction of NOx
with organic materials) constitutes a chemical hazard with a critical limit (CL) at25 ppb because of its suspected carcinogenic effect In addition mycotoxin pro-duction more than 0004 mgL and color and flavor alteration represent chemicaland physical hazards respectively The NDMA content in malt can be controlled byusing indirect heating systems or by carefully maintained and controlled low-NOx
burners Regular checks should nevertheless be carried out by the maltster so thatthe residual risk caused by polluted air is kept as low as possible (17) The finishedmalt has its rootlets removed and is screened to produce the uniform quality Duringthe malting process two important changes occur a) the barley develops its ownenzyme systems and b) the naturally produced enzymes start to break down the cellstructure of the endosperm (19) Malt quality control tests include hot water extractcolor soluble nitrogen total nitrogen moisture enzyme activities viscosity andlautering prediction tests The microbiological status of malt used in the followingsteps (CCP) is very much dependent on its handling operations after production (16)
Milling
The main function of dry or wet milling is to reduce the malt particle sizeto form grist (ground or milled grain) The particle size reduction facilitates the
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 11
extraction of soluble components mainly sugars and nitrogenous compounds fromthe endosperm (21)
Mashing (CCP3)
Mashing the first step in wort production involves extracting soluble materi-als from the milled malt This is accomplished by feeding the grist through Steelrsquosmasher a hydrator consisting of a large-bore tube bent at right angles During itspassage through the vertical portion of tube the grist is spayed with hot water (typ-ically 65C) and then mixed with the help of a revolving screw (22) The floatingendosperm particles hydrate and undergo further amylolytic scission by α- andβ-amylases Processors adjust the pH and temperature conditions to allow bothenzymes with a range of susceptibility to pH and temperature to work effectivelyNDMA production (CL = 25 ppb) as well as possible detergent residues constitutepotential chemical hazards for public health Continuous monitoring at the process-ing and adjustment of the lautering program and Cleaning In Place (CIP) systemwhen deviation occurs are proper preventive and corrective actions respectively
Lautering (CCP4)
The lauter tun is a vessel normally rinsed thoroughly with a sparging or hotwater delivery system before receiving the mash which precipitates at the flat floorof slotted stainless steel or brass plates At tun center there is a lautering machineon the shaft of which rotating rakes are attached to facilitate draining the wortinto a collection vessel called grant The wort is recirculated through the lauter tununtil it reaches a certain degree of clarity whereupon it is delivered to the kettle(21) In lautering production of Apparent Total N-nitroso compounds (ATNC)above the CL of 20 ppb constitute a CCP that should be monitored with chemicaland microbiological analyses Scheduled inspection and under-plate cleaning canprevent insufficient separation of trub from wort (23)
Boiling (CCP5)
Wort is boiled for up to 2 h at atmospheric pressure following the additionof hops (CCP) The shape of copper boiling time and temperature can affect thequality of produced beer The major objectives of wort boiling are a) wort steril-ization and enzyme inactivation b) extraction of bitter and other substances fromhops and formation of flavor compounds and c) evaporation of excess water andwort concentration evaporation of undesirable flavour volatiles Wort contamina-tion of the wort with Enterobacteriaceae from hops can result in various off-flavorsincluding ldquovegetablerdquo and ldquophenolicrdquo taints (24) Correct use of boiler treatmentchemicals steam condensate tasting for carrying over the taints and operation of
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ORDER REPRINTS
12 KOURTIS AND ARVANITOYANNIS
phenol analyses are all essential to avoid chemical contamination and taints devel-opment (23)
Clarification
Wort clarification is conducted either through sedimentation or filtrationWhen whole hop cones are used it is necessary to employ either a hop back ora hop separatorndashfilter The drop in hop usage and the widespread acceptance ofpreisomerized extracts led to utilization of a vertical cylinder known as whirlpoolwhich induces sustainable circulation of the trub collecting as a compact cone in thebase Whirlpools are more suited to larger worts and can also be used with ale Inmodern breweries centrifuges constitute a promising alternative to whirlpools (25)
Cooling
To prepare for fermentation the clear hopped wort is cooled usually in aplate heat exchanger During cooling it is advisable to aerate or even to oxygenatethe wort because next processing step involves yeast growth promoted in the pres-ence of dissolved oxygen despite the low dissolved oxygen concentration in wort(7ndash14 ppm) (22)
Fermentation (CCP6)
Fermentation aims at producing ethanol by fermenting yeasts Yeasts vary intheir behavior during fermentation some strains tend to flocculate trap plug CO2 andrising to the top whereas others do not flocculate and precipitate Several lagers areproduced by bottom fermentation while many types of ales and stouts are producedby top fermentation Saccharomyces cerevisiae is usually the top fermenting yeastin the range of 18ndash22C whilst the bottom-fermenting are strains of Saccharomycesuvarum that function in the range of 7ndash15C (26) Therefore the temperature atwhich fermentation occurs is very crucial for the further stages of beer productionThe modern use of cylindroconical vessels has reduced the fermentation periodfor ales and lagers from 7 to 2 or 3 days and from 10 to 7 days respectively (27)Fermentation is monitored by taking samples for measuring the specific gravityand can be controlled by varying the cooling rate (20) ldquoStuckrdquo fermentation wherethe required ethanol level is not attained and microbial contamination with Lacticacid bacteria mainly Lactobacilii and Pediococcus which cause taints duringmaturation or in bottle storage (28) represent microbiological hazards which arethe only hazard detected at this stage Common causes for ldquostuckrdquo fermentationinclude premature yeast flocculation and yeast failure to metabolize maltotriosedue to repression by glucose (25) A minimum of 90 viable yeast cells (CL) canbe applied to ensure the development of the process During fermentation the pH
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 13
drops from 52 to 42 and by its completion the yeast is removed either as a top orbottom crop and retained to pitch the next fermentation Apart from the conventionalmicrobial detection methods with plate count several rapid detection methodspotentially applied in breweries such as ATP bioluminescence flow cytometryand polymerase chain reaction have been developed to reduce the incubation timefrom 3ndash4 days to 1ndash2 (2930)
Maturation
Maturation includes all those changes occurring between the end of primaryfermentation to beer filtration (31) Ale is matured at relatively warm temperatures12ndash20C while lagers are held under much cooler conditions The warmer temper-atures allow the rapid metabolism of any residual and priming sugars as well asloss of green flavors within 1ndash2 weeks depending on beer type yeast strain wortcomposition and primary fermentation conditions In case of lager the beer used tobe held at refrigerated temperatures for up to several months after fermentation al-lowing formation of proteintannin complexes (18) Today the enzyme addition hassubstantially shortened this process to several weeks during which flavor maturesEnzymes such as papain may be added during transfer between fermentation andmaturation tank The dosage of the proteolytic enzyme varies depending on typeof beer and process Enzyme activity decreases progressively during maturationuntil its inactivation with pasteurization Part of the enzyme absorbed in the yeastsurface is removed during filtration (19)
Filtration (CCP7)
Beer produced during fermentation is turbid and should be clarified prior to itsmarketing This turbidity is due to the presence of yeasts and proteinaceous materi-als associated with carbohydrates and polyphenols The formation of these proteinprecipitates is attributed to cold temperature low pH and poor solubility in alcoholicsolutions (32) To prevent this from occurring in the final product the beer may besubjected to various chill-proofing treatments during its storage These treatmentsgenerally include the addition of clays to absorb the colloidal materials or prote-olytic enzymes used to further solubilize the protein fraction (33) Since oxygenuptake during this process could severely affect the product organoleptic charac-teristics a CCP of dissolved oxygen should be applied with a CL of 02 ppm (34)
Packaging and Sealing
The packing section comprises several CCPs including the containers to beused their cleaning and disinfection (CCP8) the filler line (CCP9) and the sealer(CCP10) The bursting pressure of the bottles as guaranteed by the manufacturerin his specifications for the new glass may no longer be valid in case of reusable
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ORDER REPRINTS
14 KOURTIS AND ARVANITOYANNIS
bottles due to the considerable physical stress during already exerted upon themduring the filling process Insufficient cleaning of reusable bottles due to low temper-atures and concentrations of the employed cleaning solutions as well as presence ofextraneous entrapped materials within bottles and improper emptying consist pos-sible hazards Moreover cleaning solution remnants and shards introduced throughthe procedure pose problems under working conditions The beer filler may be con-taminated by cleaning and disinfection solutions Contamination sources may bedue to inadequate pressure or faulty CIP system resulting in cleaning and disinfect-ing solution remains in the pressure tank or the ring bowl of the filler (3536) Thecrown corker should be correctly installed the filling pressure of bottle caps on themouths of the bottles should be adjusted to ensure a specified blow-off effect toavoid bottle bursting After filling there should be a full bottle inspector detectingglass particles in bottles or possible leakage (37)
Bottle Pasteurization (CCP11)
Pasteurization is carried out to ensure the beer shelf life over a period ofmonths This is accomplished by the development of tunnel pasteurization in whichthe beer bottle is subjected to 60C for 20 min Over-pasteurization which causesoxidation and can adversely affect beer flavor (38) is a potential physical hazardFurthermore it is crucial to check the time-temperature procedure with adequatecorrective actions for assuring the production of a satisfactory product
Bottle Inspection (CCP12)
Bottle inspection after the pasteurization step is important to ensure that bottleshave not been damaged during the process (39) Should such a situation occur theequipment has to be standardized by the production engineer
Labeling and Standardization (CCP13)
Labeling of the package should comply with the requirements of the CodexGeneral for the labeling of prepackaged foods (40) This means that the name of theproduct shall be clearly declared there must be a list of ingredients in descendingorder of proportion no other fruit may be represented pictorially except those usedand ldquothe date of minimum durabilityrdquo will be declared by the month and year inuncoded numerical sequence
BottleCan Packaging (CCP14)
Bottles (cans) are packaged into paperboard boxes of various sizes accordingto the bottle or can dimensions The encountered hazards can be of physical natureconcerning the bottles (cans) condition during the procedure
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 15
Storage (CCP15)
The finished beer undergoes chemical microbiological and organoleptic anal-ysis to ensure that its properties are within its specification range A synoptical pre-sentation of the occurring hazards CCPs CLs and preventive corrective measuresis given in Table 1
SAKE
Introduction
Sake is a fermented liquor made from rice and coming in many varietiesdepending on the raw materials manufacturing process and process after brewing(41) According to the earliest records sake was originally brewed from rice thathad been chewed to reach saccharification followed by natural fermentation Sakebrewed this way was used as a sacred wine in the worship of the Shinto gods Thisassociation with religion Shintoism and Buddhism has caused a deep intertwiningof sake with the traditions and social customs of Japan Thus today sake is servedat ceremonies and celebrations of all kinds (42) Sake has the highest alcoholpercentage by volume of any fermented beverage In its natural undiluted state itmay contain a potent 20 ethanol compared to 3ndash5 for beer or 9ndash12 for winewhich may reach higher values for fortified wines (4344) The central brewersrsquounion divides sake into four basic flavor types on four axes of sweet sour bitterand umai The latter is another translatorrsquos nightmare which generally ends uptranslated as delicious According to position established along these axes sakeis considered to be of ldquomature typerdquo ldquofragrant typerdquo ldquolight and smooth typerdquo orldquofull-bodied typerdquo (Fig 3) However no set of criteria can adequately express themultiplicity of sensations that together create the flavor unique to any individualsake but there is a perceived need for terms which quickly and simply give thegeneral idea
Figure 3 Main flavor types for sake characterization (43)
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ORDER REPRINTS
16 KOURTIS AND ARVANITOYANNIS
Sake Main Production Stages
The main stages for sake production are schematically presented in Figure 4
Raw Materials (CCP1)
The main ingredients of Japanese sake are rice sake rice sake yeastand water The rice most suitable for sake should consist of large grains and shouldbe soft with a white part at its center due to coarse cell structure Rice should complywith the maximum residue limits for pesticides and insecticides established by theCodex Alimentarius Commission for this commodity (45) (CCP chemical hazard)For Japanese sake yellow koji mold (Aspergillus oryzae) is used Sake yeast (Sac-charomyces cerevisiae) is a microbe converting the occurring glucose and mineralsin rice and water into alcohol Employment of bubble-free type yeast eliminates
Figure 4 Process flow diagram of sake production (264647)
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 17
the bubble removal step thus shortening the brewing period and reducing the costShould the factory wish to employ a specific yeast an adequate disinfection ofthe building interior is required otherwise undesirable bacteria may be introducedwhich could prove hazardous to human health (CCP microbiological hazard) (46)
Rice Polishing (CCP2)
The brown rice used for sake production must be first polished to remove theouter portion of the grain which contains fats proteins minerals and amino acidsthat can cause unpleasant flavors leaving the starch residues that are located in thecenter of the grain Nowadays machines are programmed to automatically removewhatever portion of the rice is required for the specific sake (47) The rice polishingratio (73ndash35) is expressed by the following formula (43)
Rice polishing ratio=(weight of white riceweight of brown rice)times100 (1)
The polishing process should be gently carried out because friction results inheat generation thereby greatly affecting water absorption and rice grain structureBroken grains are unlikely to satisfactorily ferment (47) Maybe the most importantstage in sake production consists of yeast starter mash production which can takeplace either with the classical Kimoto or slightly revised Yamahai process or withthe new ldquohigh speedrdquo methods (48)
Washing (CCP3)
After the rice has been polished rice powder clinging to the grain surface isremoved by washing Washing can be carried out either mechanically or manually(laborious hand washing) and should result in removing most of the organic andinorganic impurities reaching the CLs set by Codex Alimentarius of 15 and01 mm respectively
Soaking (Steeping)
Soaking allows rice to absorb the desired amount of water that is crucial toestablishing the rice consistency For sake produced ldquoen masserdquo simply dumpinginto a vat overnight for as long as 14 h is a usual case (47) However high polishedrice may be soaked within minutes In such a case an error of a minute might proveto have dire consequences for the end product (43)
Steaming (CCP4)
Steaming aims at softening the rice grains and breaking down the starchmolecules thus encouraging the growth of Aspergillus oryzae and eliminating all
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ORDER REPRINTS
18 KOURTIS AND ARVANITOYANNIS
other microorganisms leaving an initially sterile environment prone to sake moldpropagation Presence of lactic acid bacteria (LAB) and yeasts may occur at theend of this step representing a microbiological hazard and resulting in consider-able organoleptic losses The time can vary from 20 to 60 min depending on thebrewer and apparatus employed (40ndash60 and 20 min for traditional and automatedrespectively) (4346)
Cooling
The ensuing division of steamed rice is mainly related to its further use Apart of it is directly cooled by air blower whereas 20ndash30 is transferred to a heatedculture room to be infected with bacteria spores (Aspergillus oryzae) for sake moldproduction
Koji
Since rice grains contain no sugar it is the action of koji mold that converts thestarch in the grains to sugar The steamed rice is first cooled to 15ndash36C before beingtransferred to the koji culture room (30C) Spores of the mold are sprinkled likefine dust on the rice when it has cooled down to 33C After the spores are kneadedinto the steamed rice the rice is heaped and wrapped in cloths to prevent heat andmoisture loss which are two crucial factors for satisfactory bacterial growth Tomaintain uniform temperature and moisture rice is spread and mixed twice the firsttime after 20 hours (upon the appearance of white flecks) and then 7ndash8 h thereafteraccompanied by a distinctive aroma release (48)
Main Mash (Moromi) and Fermentation (CCP5)
In fermentation the occurring chemical hazards are related to heavy metalspresence (As lt 02 Cd lt 001 Pb lt 03 mgL) pesticide residues (as mentionedin Codex Alimentarius) and residues of detergents (absence) and ethylene glycole(absence) Their CLs can be determined and monitored with specific chemicalanalyses The ingredients of main mash (water koji rice and steamed rice) areadded to the starter mash in three steps (moving from small to bigger recipient)over a period of 4 days at successively lower temperatures thus preventing thegrowth of airborne bacteria (Table 2) A day after the addition of all the ingredientsformation of a moist surface showing clear cracks occurs Furthermore the mashbegins to bubble (indication of fermentation progress) as gas is given off during theburgeoning fermentation The fermentation can take place at various temperaturesand its duration depends on it that is at lower temperatures it takes up to twoweeks but the sake aroma is much more appealing compared to that formed athigher temperatures The characteristic sake aroma results from combined flavor
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 19
Table 2 Quantities of Ingredients at Each Stage of Mixing the Main Mash (Moromi)
Yeast 1st 2nd 3rd 4thStarter (Moto) Addition Addition Addition Additiona Total
Total rice (kg) 210 470 850 1470 3000Steamed rice (kg) 140 330 650 1230 2350Koji rice (kg) 70 140 200 240 65030 Brewerrsquos 1200 1200
alcohol (L)Water (L) 230 420 1010 2030 360 405
aTraditional brewers mix the final mash in three stages The fourth addition of alcohol and wateris a controversial postwar development (Kondo 1984)
components of a number of compounds produced during fermentation (49) Theelevated alcohol content of the fermented sake is related to lipid metabolism ofyeast in the presence of proteolipid provided by the koji molds (5051)
Additions (CCP6)
The addition of alcohol at this stage is carried out unless it is clearly statedthat sake does not contain any alcohol from extraneous sources The added alcoholshould not contain methanol or if it does the content of the latter should be lessthan 05 gL because of its toxicity (CCP chemical hazard)
Pressing
Automatic machine presses (consisting of a series of panels with balloon-likesacks attached) are most widely used nowadays instead of the traditional time-consuming method using long bags The remained caked lees are employed forpickle production and cooking or sedimentation of rice particles may occur Alter-natively sedimentation of rice particles at the bottom of the tank may take place
Filtration
Coloring and aging (maturation) inhibition can be effected by using activatedcharcoal filters
Pasteurization (CCP7 and CCP8)
Heating sake preferably twice at 65C kills off the remaining yeast stops en-zyme action and deactivates the lactic acid bacteria that will eventually spoil sakeThis process represents a microbiological hazard for which the specific plant may
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ORDER REPRINTS
20 KOURTIS AND ARVANITOYANNIS
set CLs However in recent years refrigerated storage and transport have madeunpasteurized sake with characteristic aroma available to the consumer (43)
Dilution
The produced sake in its raw state (Genchu) contains more than 20 alcoholby volume but it is generally diluted to about 15ndash16 vol-
BottlingStorageDistribution
The applied procedures are similar to those mentioned for the beer productionA summary of the occurring hazards CCPs CLs and preventive and correc-
tive measures is given in Table 3
WINE
Introduction
Wines are made from the fruit of Vitis vinifera of which there are a greatnumber of varieties growing in many parts of the world The history of wine isinextricably interwoven with human history It might be as true to say that it waswith wine that civilization began for the vine takes longer to mature than any othercrop and does not produce grapes for wine making until its fourth year It is notexactly known when men first had wine but it was accepted as a gift from the godsthe Egyptians attributed it to Osiris and the Greeks to Dionysos Mesopotamia andthe Caucasian slopes were no doubt early sources of wine from where it was spreadto Egypt and Greece and then to the rest of the world (52)
Wine Main Production Stages
The main stages for wine production are schematically presented in Figure 5
Harvesting (CCP1)
Grape harvesting is a CCP comprising both physical and chemical hazardsPhysically the grapes should be sound without rotten parts otherwise oxidativeand microbial contamination can rapidly develop Therefore harvesting shouldbe conducted with the greatest possible care and an efficient disease managementsystem should be applied (5354) Pesticides play an important role in pest man-agement but they should be handled with care because they constitute chemicalhazards (55) At the time of harvest the grapes must have also reached the correctmaturity when Brix and Total Acidity (TA) levels indicate maturity of wine Sincepesticide and fungicide residues on the surface of the berries constitute chemical
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 21
hazards Oliva et al (56) proposed a rapid and simple gas chromatographic methodfor their determination The maximum residue limits for pesticides in grapes andwines are provided by Codex Alimentarius (45) and Organisation International duVin (57) Finally the bulk bins used for grapes transportation should be effectivelydecontaminated to avoid any microbial infection
Stemming
Stemming includes the removal of stem leaves and grape stalks before crush-ing This procedure has several advantages because the total volume of processedproduct drops by 30 thus resulting in smaller tanks and eventually increasingthe productrsquos alcoholic content (58) However the end of fermentation and the al-cohol content of finished product depend mostly on the Brix level of initial grapesStemmers usually contain a perforated cylinder allowing berries to pass throughbut prevent the passage of stems stalks and leaves
Crushing
Crushing typically immediately follows stemming since some crushing ofthe fruit occurs during stemming The released juice is highly susceptible to oxida-tive browning and microbial contamination The most common crushing processesinvolve pressing the fruit against a perforated wall or passing the fruit through a setof rollers It is very important to avoid crushing the seeds to preclude contaminat-ing the must with seed oils the oxidation of which could produce rancid odors andconstitute an undesirable source of bitter tannins Equally important is the properhandling of product because inappropriate timing might lead to a sudden startof alcoholic fermentation and consequently to higher fermentation temperatureswhile a delay might cause microbial contamination and oxidative browning (59)
Maceration
Maceration is the breakdown of grape solids after crushing of grapes Whilemaceration is always involved in the initial stage of red wine fermentation the long-standing trend has been to limit maceration in white wine production Temperatureand duration of maceration depend on grape and wine variety Usually for white androse wines the maceration time is less than 24 h red destined for early consumptionis macerated for 3ndash5 days and red for aging is macerated from 5 days to 3 weeksFermentation usually occurs during this or at the end of maceration The amount ofthe antimicrobial to be used usually added to white musts that are most sensitive tooxidation depends on the crop health and maceration temperature Sulfur dioxidehas a distinct advantage over other antimicrobial agents because of the relativeinsensitivity of the wine yeasts to its action However it is also toxic or inhibitoryto most bacteria and yeasts (ie Candida Pichia Hansenula) at low concentrations(60) and has a rather low retention capability after the clarification step (61)
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ORDER REPRINTS
22 KOURTIS AND ARVANITOYANNISTa
ble
3Su
mm
ary
ofH
azar
dsC
CPs
CL
sM
onito
ring
Cor
rect
ive
Act
ions
and
Pers
onne
lRes
pons
ible
for
Sake
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
a(M
CP
)bM
easu
res
CC
PPa
ram
eter
(CL
s)Pr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
CC
ertifi
edsu
pplie
rs
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
wat
er
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Cer
tified
supp
liers
Hea
vym
etal
spr
esen
cein
wat
er
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Eva
luat
ion
ofth
ede
cont
amin
atin
gm
etho
ds
MC
ertifi
edsu
pplie
rs
prop
erpr
epar
atio
n
Mic
robi
alco
ntam
inat
ion
ofth
ecu
lture
100
clea
nM
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Wat
erm
icro
biol
ogic
alqu
ality
Abs
ence
ofpa
thog
ens
Insp
ectio
nof
the
equi
pmen
t
Ric
epo
lishi
ng(C
CP2
)C
Cer
tified
supp
lier
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
polis
hed
rice
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Was
hing
(CC
P3)
PC
ertifi
edsu
pplie
rs
inst
alla
tion
ofau
tom
atic
sepa
rato
r
Ani
mal
impu
ritie
sO
ther
orga
nic
and
inor
gani
cm
ater
01
mm
15
mm
01
mm
Spec
ific
exam
inat
ion
Rew
ashi
ngof
spec
ific
batc
hch
ange
supp
lier
Qua
lity
cont
rol
man
ager
Stea
min
g(f
orun
past
euri
sed
sake
)(C
CP4
)
MG
MP
sche
dule
dm
icro
biol
ogic
alco
ntro
ls
Pres
ence
ofye
asts
and
LA
B
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Spec
ific
batc
hre
proc
essi
ng
CIP
stan
dar-
disa
tion
Qua
lity
cont
rol
man
ager
T
rain
ned
pers
onne
l
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irel
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 23
Ferm
enta
tion
(CC
P5)
CM
ater
ialc
ontr
ol
GM
Pco
rros
ion
chec
ks
Hea
vym
etal
pres
ence
Pest
icid
ere
sidu
es
Aslt
02
Cd
lt
001
Pb
lt
03
(mg
L)
Spec
ific
chem
ical
anal
ysis
Dem
etal
lisat
ion
Cha
nge
supp
lier
Rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
GM
Pus
eof
nont
oxic
glyc
ole
Res
idue
sof
ehty
lene
glyc
ole
ampde
terg
ents
0Sp
ecifi
cch
emic
alan
alys
isD
ilutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Alc
ohol
addi
tion
(CC
P6)
CC
ertifi
edsu
pplie
rM
etha
nolc
onte
ntlt
05
gL
GC
exam
inat
ion
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erPa
steu
riza
tion
(CC
P7amp
CC
P8)
MR
unni
ngof
past
euri
ser
acco
rdin
gto
prog
ram
Det
ectio
nof
yeas
tsL
AB
en
zym
atic
activ
ity
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Tem
pera
ture
adju
stm
ent
batc
hre
proc
essi
ng
prop
erm
achi
nery
disi
nfec
tion
Qua
lity
cont
rol
man
ager
Tech
nica
lm
anag
er
aR
egar
ding
the
proc
edur
esof
bottl
ing
stor
age
and
dist
ribu
tion
the
CC
Psar
esi
mila
rto
thos
em
entio
ned
inTa
ble
1fo
rbe
erpr
oduc
tion
bM
CP
stan
dfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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2011
ORDER REPRINTS
24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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2011
ORDER REPRINTS
26 KOURTIS AND ARVANITOYANNIS
Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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2011
ORDER REPRINTS
28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
Dow
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
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ded
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irel
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] at
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ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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] at
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
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itesi
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
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itesi
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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2 KOURTIS AND ARVANITOYANNIS
aiming at zero defect products it is well known that this is not feasible and thereal target is the minimization of unacceptable unsafe products When a companydecides to adopt HACCP it should be able to set controls at each point of theproduction line at which safety problems (physical chemical and microbiological)are likely to occur (3)
Prior to initiating a HACCP system a company must endeavor to put togethera HACCP plan most often described by the five following steps (1345) a) identifyHACCP resources and assemble the team b) describe the food and its distributionmethod c) state clearly intended use and consumers and d) develop a process flowdiagram and e) verify the validity of this diagram in practice (operation)
The regulatory requirements for Sanitation Standard Operating Procedures(SSOPs) in conjunction with Good Manufacturing Practices (GMPs) should alsobe considered as a prerequisite to HACCP The following seven HACCP principlesconstituting the major steps to writing an HACCP (637)
1 Conduct a hazard analysis2 Identify critical control points (CCPs) by applying the HACCP decision
tree (8 Fig 1)3 Establish critical limits (CLs) for each CCP4 Establish monitoring actions5 Establish corrective actions6 Establish record-keeping procedures7 Establish verification procedures
Today HACCP is continuously gaining importance and worldwide acceptabil-ity being implemented by most countries all over the world The implementation ofHACCP in the EU in particular was introduced by the Council Directives 914393and 92592 HACCPrsquos implementation is considerably facilitated when other com-plementary quality assurance systems (ISO 90012) are already in place (9) Thecurrent tendency is integrating HACCP and ISO 9001 or ISO 9002 (1011) withinthe frame of Total Quality Management
Since the two most important stages for the drink industry are fermentationand bottling where hazards are likely to occur special care is required (trainedpersonnel sanitation equipment maintenance GMP)
This review article aims to present an overview of HACCP implementation toalcoholic beverages through the production and distribution chains and to pinpointthe current CCPs CLs and preventive and corrective actions due to be undertakenin case any deviations are observed
BEER
Introduction
Beer is an alcoholic beverage produced by the fermentation of wort obtainedfrom barley malt flavored with hops The alcoholic content of beer ranges from 4
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 3
Figure 1 HACCP decision tree (102)
for ordinary beer up to 15 Beerrsquos first production in Mesopotamia by the Sume-rians in the 5th millennium BC classifies it among the most ancient of alcoholicbeverages Towards the middle of the 3rd millennium BC there is documentary evi-dence of beer drinking by the Egyptians who probably introduced beer technology
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4 KOURTIS AND ARVANITOYANNIS
in Europe Beer drinking in northern Europe dates back to early antiquity contraryto the Mediterranean countries in which wine was the commonest drink A criticalpoint in its history was the works of Louis Pasteur which greatly contributed to theunderstanding of beer production (12)
Beer Main Production Stages
The main stages for beer production are shown schematically in Figure 2together with their critical control point (CCP) numbers
Incoming Raw Materials (CCP1)
The principal raw materials used to brew beer are water malted barley hopsand yeast Barley is required to be of sufficiently good malting quality in order togerminate and to produce a satisfactory product yield Other factors such as dor-mancy and losses during malting have also to be considered (13) The malting orsubsequent brewing characteristics are subtly affected by the weather conditionsprevailing over the growing period Some information regarding the quality of abatch of barley can be obtained by visual inspection but usually it is complementedby analyses including moisture content total nitrogen 1000-grain weight and theportion of nongerminating grain The National Institute of Agricultural Botany(UK) provides descriptions of the European malting varieties Residues of certainpesticides used on malting barley survive through to the final malt and wort and canaffect the process and quality of the end product (CCP) Fungicides and herbicidesinfluencing enzyme synthesis during malting process can accumulate in the yeastthereby affecting the next fermentation (14) The critical limits of these substancesare prescribed by Codex Alimentarius and are presented in Table 1 Presence ofheavy metals above the specifications of Directive 80776EC and mycotoxin pro-duction more than 004 mgL mainly from Fusarium species such as aflatoxinsochratoxine A zearoleon deoxyniralenol constitutes a high risk for human health(CCP) (15) Temperature and relative humidity are two interacting parameters thatdefine the germination of spores of different microorganisms (16) Visual inspec-tion and biological plate methods detect the fungal contamination for mycotoxinanalysis employment of HPLC or ELISA is required (17)
The quality of the water used is a major factor affecting the beer quality(CCP) The development of strict water control standards was introduced by mostbreweries in which water is filtered through activated carbon as well as ion ex-change resins to remove impurities (pesticides herbicides and industrial wastes)Two ions of particular importance in water are calcium and carbonatebicarbonatewhich control the pH during brewing Calcium also protects α-amylase from heatdestruction thereby permitting liquefaction of starch during mashing (18)
Hops not only provide bitter flavor to the beer but impart a hoppy characteras well These aroma components are derived from the essential oil The brewing
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 5
Figure 2 Process flow diagram of beer production (2226)
value of hops depends on the resin fraction which amounts to 15 and the essentialoil comprising sim05 Total resin is defined as the material soluble in both coldmethanol and diethyl ether ldquosoftrdquo resin is that proportion of the total which issoluble in hexane comprising mainly α and β-acids while ldquohardrdquo resin is insolublein hexane The α-acids that are the most significant bittering precursors can bedistinguished from other soft resins from their ability to form a lead salt which isinsoluble in methanol The determination of moisture and seed content also provideuseful conclusions about their quality (13) Adjuncts of carbohydrate origin other
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ORDER REPRINTS
6 KOURTIS AND ARVANITOYANNIS
Tabl
e1
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rB
eer
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Mon
itori
ngC
orre
ctiv
eR
espo
nsib
lePr
oces
sSt
ep(P
MC
)aM
easu
res
CC
PPa
ram
eter
Cri
tical
Lim
itPr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
fung
ide
velo
pmen
tte
mpe
ratu
rean
dR
Hre
gula
tion
duri
ngst
orag
e
Myc
otox
inpr
oduc
tion
000
4m
gL
Vis
uali
nspe
ctio
nof
fung
ide
velo
pmen
tH
PLC
EL
ISA
E
PSan
alys
is
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
er
Cer
tified
supp
liers
sc
hedu
lein
spec
tions
Pres
ence
ofE
nter
o-ba
cter
iace
ae
0M
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Cha
nge
supp
lier
Stri
cktly
follo
win
gin
stru
ctio
nsC
onta
min
atio
nof
mic
robi
alpr
epar
atio
ns
100
clea
nC
hang
epr
epar
atio
nm
etho
dC
Effi
cien
tdis
ease
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
barl
eyh
ops
wat
er
By
pest
icid
eas
desc
ribe
dby
Cod
ex
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erC
ertifi
edsu
pplie
rsPr
oper
wat
erde
cont
amin
atio
nH
eavy
met
als
pres
ence
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Rej
ectio
nof
spec
ific
batc
hD
e-m
etal
lisat
ion
step
Use
ofde
ioni
ser
Wat
errsquos
elec
tric
alco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nise
r
Aut
omat
icdi
scon
tinua
tion
ofde
ioni
ser
anal
ysis
ofw
ater
sam
ples
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 7
Mal
ting
(CC
P2)
CU
seof
indi
rect
heat
ing
syst
ems
cont
roll
ow-N
Ox
burn
ers
ND
MA
prod
uctio
ndu
ring
kiln
ing
25
ppb
Con
tinuo
usch
ecki
ngth
ear
eas
peci
fican
alys
es
Rej
ectio
nor
mix
ing
with
othe
rba
tche
s
Qua
lity
cont
rol
man
ager
PC
ontr
olof
time
tem
pera
ture
and
RH
Col
our
and
flavo
urde
velo
pmen
tSp
ecifi
edby
part
icul
arpl
ant
Con
tinuo
usm
onito
ring
ofpr
oces
sing
cond
ition
s
Mix
ing
with
othe
rm
alts
rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
MPr
oper
hadl
ing
oper
atio
nsaf
ter
prod
uctio
n
Myc
otox
inpr
oduc
tion
000
4m
gL
Vis
uali
nspe
ctio
nof
fung
ide
velo
pmen
tH
PLC
EL
ISA
E
PSan
alys
is
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
er
Mas
hing
(CC
P3)
CC
ontr
olof
tem
pera
ture
CIP
ND
MA
prod
uctio
nde
terg
ent
resi
dues
25
ppb
Non
eC
ontin
uous
reco
rdin
gof
the
proc
essi
ng
Adj
ustl
aute
ring
prog
ram
Qua
lity
cont
rol
man
ager
Lau
teri
ng(C
CP4
)C
Sche
dule
Insp
ectio
nun
der
plat
ecl
eani
ng
AT
NC
lt20
ppb
Mic
robi
olog
ical
and
chem
ical
anal
yses
Prop
erm
aint
ain
re-l
aute
ring
ofth
eba
tch
Qua
lity
cont
rol
man
ager
Boi
ling
(CC
P5)
CC
orre
ctus
eof
boile
rtr
eatm
ent
chem
ical
s
Con
tam
inat
ion
with
dete
rgen
ts0
CIP
syst
emR
epai
rC
IPb
atch
reje
ctio
nQ
ualit
yco
ntro
lm
anag
erFe
rmen
tatio
n(C
CP6
)M
Aer
atio
nof
wor
tus
eof
yeas
tfor
max
6ge
nera
tions
Poor
yeas
tvi
abili
tyldquo
stuc
krdquofe
rmen
tatio
n
Min
90
viab
leye
astc
ell
Yea
stco
ncen
trat
ion
ferm
enta
bilit
yO
2co
ncen
trat
ion
inth
ew
ort
Incr
ease
prop
agat
ion
freq
uenc
yw
ort
aera
tion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
8 KOURTIS AND ARVANITOYANNIS
Tabl
e1
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Mon
itori
ngC
orre
ctiv
eR
espo
nsib
lePr
oces
sSt
ep(P
MC
)aM
easu
res
CC
PPa
ram
eter
Cri
tical
Lim
itPr
oced
ures
Act
ions
Pers
onne
l
Ferm
enta
tion
(CC
P6)
MIn
spec
tion
ofC
IPsy
stem
and
equi
pmen
t
Lac
toba
cill
iac
etic
acid
bact
eria
and
wil
dye
asts
Pres
ence
in1
mL
plat
e+1
mL
actid
ione
Plat
eco
unt
met
hod
ora
rapi
dde
tect
ion
met
hod
Prop
erdi
sinf
ectio
nof
equi
pmen
tre
proc
essi
ngof
the
batc
h
Qua
lity
cont
rol
man
ager
Filtr
atio
n(C
CP7
)C
Use
CO
2
prefi
lling
offil
ter
with
wat
er
O2
upta
kegt
02
ppm
diss
olve
dO
2
Mea
sure
men
tof
diss
olve
dO
2
Surv
eyof
filtr
atio
nfo
rin
crea
sed
O2
pick
up
Qua
lity
cont
rol
man
ager
Bot
tlec
anin
spec
tor
(CC
P8)
CG
MP
Cle
anin
gpe
rfor
man
ceN
oso
lids
noliq
uid
rem
nant
sE
labo
rate
elec
tron
icre
cogn
ition
syst
ems
afte
rC
IP
Rew
ashi
ngof
bottl
esC
IPsy
stem
insp
ectio
n
Qua
lity
cont
rol
man
ager
PC
ertifi
edsu
pplie
rpr
oper
hand
ling
ofbo
ttles
Bot
tles
prop
erfo
rfo
ods
and
drin
ks
bottl
esco
nditi
on
Cra
cks
scra
tche
sab
senc
eO
n-lin
evi
sual
cont
rol
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlec
anfil
ler
(CC
P9)
CIn
stal
latio
nof
cont
rolli
ngeq
uipm
ento
nth
eC
IPsy
stem
Con
tam
inat
ion
with
dete
rgen
tsC
ompl
ete
abse
nce
Org
anol
eptic
exam
inat
ion
offil
led
bottl
es
Bat
chre
ject
ion
Tra
ined
pers
onne
l
Bot
tlec
anse
aler
(CC
P10)
PC
orre
ctin
stal
latio
nof
equi
pmen
tB
low
-off
effe
ctO
ccur
renc
ere
duce
dto
anac
cept
able
leve
l
Con
trol
sets
ealin
gpr
essu
reA
utom
atic
rem
oval
ofde
stro
yed
bottl
es
Tra
ined
pers
onne
l
Bot
tlec
anpa
steu
riza
tion
(CC
P11)
PR
unni
ngpa
steu
rise
rac
cord
ing
topr
ogra
m
Oxi
datio
nca
used
ofw
rong
tem
pera
ture
-tim
ese
t
Max
65 C
for
20m
inq
uick
cool
ing
atth
eex
it
Con
tinuo
uson
-lin
etim
e-te
mpe
ratu
rech
ecki
ng
Adj
ust
tem
pera
ture
m
aint
ain
equi
pmen
t
Tech
nica
lm
anag
er
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 9
Bot
tlec
anin
spec
tion
(CC
P12)
PR
egul
arin
spec
tion
ofth
em
achi
nery
Phys
ical
dam
age
Occ
urre
nce
redu
ced
toan
acce
ptab
lele
vel
On-
line
mon
itori
ngE
quip
men
tst
anda
rdis
atio
nTe
chni
cal
man
ager
Lab
elin
g(C
CP1
3)P
Car
eful
sele
ctio
nof
the
etiq
uette
sM
ispl
aced
etiq
uette
sR
educ
edto
anac
cept
able
leve
lV
isua
lche
cks
cont
rolo
fth
eeq
uipm
ent
Rel
abel
ing
the
spec
ific
batc
hT
rain
edpe
rson
nel
Bot
tlec
anpa
ckag
ing
(CC
P14)
PC
orre
ctin
stal
latio
nof
the
equi
pmen
tB
ottle
sco
nditi
ondu
ring
palle
tisat
ion
Abs
ence
ofri
fts
inth
elu
tec
rack
orsc
ratc
hes
On-
line
visu
alco
ntro
lA
djus
tthe
equi
pmen
tpa
ram
eter
s(s
peed
pre
ssur
e)
Tech
nica
lm
anag
er
Stor
age
(CC
P15)
PC
ontr
olst
orag
eco
nditi
ons
Org
anol
eptic
cond
ition
ofbe
erSp
ecifi
edby
the
part
icul
arpl
ant
Sche
dule
dco
ntro
lsof
finis
hed
prod
uct
Adj
ustt
hest
oreh
ouse
cond
ition
s
Tra
ined
pers
onne
l
aP
MC
stan
dfo
rph
ysic
alm
icro
biol
ogic
alan
dch
emic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
10 KOURTIS AND ARVANITOYANNIS
than malt are sometimes used as an additional source of extract to supplementmalt Unmalted cereal adjuncts usually contain no active enzymes and thereforerely on malt or exogenous enzymes to provide the necessary enzymes for starchconversion (19)
Yeast growth cannot be separated from the fermentation process and it isnecessary to the production of both beer and fresh yeast for use in subsequentfermentations The quality control of yeasts comprises a) the selection maintenanceand supply of a suitable strain and b) the routine assessment of purity and detectionof microbial contamination (CCP) (20)
Malting (CCP2)
This process involves steeping the barley in a shallow bed of water at a tem-perature of 10ndash15C so that its moisture content amounts to 45 wt- of barleyBarley is then allowed to germinate under controlled temperature conditions atapproximately 15C and RH100 with constant turning to prevent matting therootlets The barleycorn undergoes germination through air passage via the germi-nating malt for 3ndash5 days Gentle heating stops germination due to moisture removaland promotes formation of flavor compounds The kiln temperature regime is cru-cial for the color of malt and the survival of enzymes to be used in the mashingprocess Kilning duration usually varies between 24 and 48 h Time temperatureand moisture content are varied to control color and flavor development Chemicalmicrobiological and physical hazards may be encountered in this step In partic-ular nitrosodimethylamine (NDMA) production during kilning (reaction of NOx
with organic materials) constitutes a chemical hazard with a critical limit (CL) at25 ppb because of its suspected carcinogenic effect In addition mycotoxin pro-duction more than 0004 mgL and color and flavor alteration represent chemicaland physical hazards respectively The NDMA content in malt can be controlled byusing indirect heating systems or by carefully maintained and controlled low-NOx
burners Regular checks should nevertheless be carried out by the maltster so thatthe residual risk caused by polluted air is kept as low as possible (17) The finishedmalt has its rootlets removed and is screened to produce the uniform quality Duringthe malting process two important changes occur a) the barley develops its ownenzyme systems and b) the naturally produced enzymes start to break down the cellstructure of the endosperm (19) Malt quality control tests include hot water extractcolor soluble nitrogen total nitrogen moisture enzyme activities viscosity andlautering prediction tests The microbiological status of malt used in the followingsteps (CCP) is very much dependent on its handling operations after production (16)
Milling
The main function of dry or wet milling is to reduce the malt particle sizeto form grist (ground or milled grain) The particle size reduction facilitates the
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 11
extraction of soluble components mainly sugars and nitrogenous compounds fromthe endosperm (21)
Mashing (CCP3)
Mashing the first step in wort production involves extracting soluble materi-als from the milled malt This is accomplished by feeding the grist through Steelrsquosmasher a hydrator consisting of a large-bore tube bent at right angles During itspassage through the vertical portion of tube the grist is spayed with hot water (typ-ically 65C) and then mixed with the help of a revolving screw (22) The floatingendosperm particles hydrate and undergo further amylolytic scission by α- andβ-amylases Processors adjust the pH and temperature conditions to allow bothenzymes with a range of susceptibility to pH and temperature to work effectivelyNDMA production (CL = 25 ppb) as well as possible detergent residues constitutepotential chemical hazards for public health Continuous monitoring at the process-ing and adjustment of the lautering program and Cleaning In Place (CIP) systemwhen deviation occurs are proper preventive and corrective actions respectively
Lautering (CCP4)
The lauter tun is a vessel normally rinsed thoroughly with a sparging or hotwater delivery system before receiving the mash which precipitates at the flat floorof slotted stainless steel or brass plates At tun center there is a lautering machineon the shaft of which rotating rakes are attached to facilitate draining the wortinto a collection vessel called grant The wort is recirculated through the lauter tununtil it reaches a certain degree of clarity whereupon it is delivered to the kettle(21) In lautering production of Apparent Total N-nitroso compounds (ATNC)above the CL of 20 ppb constitute a CCP that should be monitored with chemicaland microbiological analyses Scheduled inspection and under-plate cleaning canprevent insufficient separation of trub from wort (23)
Boiling (CCP5)
Wort is boiled for up to 2 h at atmospheric pressure following the additionof hops (CCP) The shape of copper boiling time and temperature can affect thequality of produced beer The major objectives of wort boiling are a) wort steril-ization and enzyme inactivation b) extraction of bitter and other substances fromhops and formation of flavor compounds and c) evaporation of excess water andwort concentration evaporation of undesirable flavour volatiles Wort contamina-tion of the wort with Enterobacteriaceae from hops can result in various off-flavorsincluding ldquovegetablerdquo and ldquophenolicrdquo taints (24) Correct use of boiler treatmentchemicals steam condensate tasting for carrying over the taints and operation of
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ORDER REPRINTS
12 KOURTIS AND ARVANITOYANNIS
phenol analyses are all essential to avoid chemical contamination and taints devel-opment (23)
Clarification
Wort clarification is conducted either through sedimentation or filtrationWhen whole hop cones are used it is necessary to employ either a hop back ora hop separatorndashfilter The drop in hop usage and the widespread acceptance ofpreisomerized extracts led to utilization of a vertical cylinder known as whirlpoolwhich induces sustainable circulation of the trub collecting as a compact cone in thebase Whirlpools are more suited to larger worts and can also be used with ale Inmodern breweries centrifuges constitute a promising alternative to whirlpools (25)
Cooling
To prepare for fermentation the clear hopped wort is cooled usually in aplate heat exchanger During cooling it is advisable to aerate or even to oxygenatethe wort because next processing step involves yeast growth promoted in the pres-ence of dissolved oxygen despite the low dissolved oxygen concentration in wort(7ndash14 ppm) (22)
Fermentation (CCP6)
Fermentation aims at producing ethanol by fermenting yeasts Yeasts vary intheir behavior during fermentation some strains tend to flocculate trap plug CO2 andrising to the top whereas others do not flocculate and precipitate Several lagers areproduced by bottom fermentation while many types of ales and stouts are producedby top fermentation Saccharomyces cerevisiae is usually the top fermenting yeastin the range of 18ndash22C whilst the bottom-fermenting are strains of Saccharomycesuvarum that function in the range of 7ndash15C (26) Therefore the temperature atwhich fermentation occurs is very crucial for the further stages of beer productionThe modern use of cylindroconical vessels has reduced the fermentation periodfor ales and lagers from 7 to 2 or 3 days and from 10 to 7 days respectively (27)Fermentation is monitored by taking samples for measuring the specific gravityand can be controlled by varying the cooling rate (20) ldquoStuckrdquo fermentation wherethe required ethanol level is not attained and microbial contamination with Lacticacid bacteria mainly Lactobacilii and Pediococcus which cause taints duringmaturation or in bottle storage (28) represent microbiological hazards which arethe only hazard detected at this stage Common causes for ldquostuckrdquo fermentationinclude premature yeast flocculation and yeast failure to metabolize maltotriosedue to repression by glucose (25) A minimum of 90 viable yeast cells (CL) canbe applied to ensure the development of the process During fermentation the pH
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 13
drops from 52 to 42 and by its completion the yeast is removed either as a top orbottom crop and retained to pitch the next fermentation Apart from the conventionalmicrobial detection methods with plate count several rapid detection methodspotentially applied in breweries such as ATP bioluminescence flow cytometryand polymerase chain reaction have been developed to reduce the incubation timefrom 3ndash4 days to 1ndash2 (2930)
Maturation
Maturation includes all those changes occurring between the end of primaryfermentation to beer filtration (31) Ale is matured at relatively warm temperatures12ndash20C while lagers are held under much cooler conditions The warmer temper-atures allow the rapid metabolism of any residual and priming sugars as well asloss of green flavors within 1ndash2 weeks depending on beer type yeast strain wortcomposition and primary fermentation conditions In case of lager the beer used tobe held at refrigerated temperatures for up to several months after fermentation al-lowing formation of proteintannin complexes (18) Today the enzyme addition hassubstantially shortened this process to several weeks during which flavor maturesEnzymes such as papain may be added during transfer between fermentation andmaturation tank The dosage of the proteolytic enzyme varies depending on typeof beer and process Enzyme activity decreases progressively during maturationuntil its inactivation with pasteurization Part of the enzyme absorbed in the yeastsurface is removed during filtration (19)
Filtration (CCP7)
Beer produced during fermentation is turbid and should be clarified prior to itsmarketing This turbidity is due to the presence of yeasts and proteinaceous materi-als associated with carbohydrates and polyphenols The formation of these proteinprecipitates is attributed to cold temperature low pH and poor solubility in alcoholicsolutions (32) To prevent this from occurring in the final product the beer may besubjected to various chill-proofing treatments during its storage These treatmentsgenerally include the addition of clays to absorb the colloidal materials or prote-olytic enzymes used to further solubilize the protein fraction (33) Since oxygenuptake during this process could severely affect the product organoleptic charac-teristics a CCP of dissolved oxygen should be applied with a CL of 02 ppm (34)
Packaging and Sealing
The packing section comprises several CCPs including the containers to beused their cleaning and disinfection (CCP8) the filler line (CCP9) and the sealer(CCP10) The bursting pressure of the bottles as guaranteed by the manufacturerin his specifications for the new glass may no longer be valid in case of reusable
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ORDER REPRINTS
14 KOURTIS AND ARVANITOYANNIS
bottles due to the considerable physical stress during already exerted upon themduring the filling process Insufficient cleaning of reusable bottles due to low temper-atures and concentrations of the employed cleaning solutions as well as presence ofextraneous entrapped materials within bottles and improper emptying consist pos-sible hazards Moreover cleaning solution remnants and shards introduced throughthe procedure pose problems under working conditions The beer filler may be con-taminated by cleaning and disinfection solutions Contamination sources may bedue to inadequate pressure or faulty CIP system resulting in cleaning and disinfect-ing solution remains in the pressure tank or the ring bowl of the filler (3536) Thecrown corker should be correctly installed the filling pressure of bottle caps on themouths of the bottles should be adjusted to ensure a specified blow-off effect toavoid bottle bursting After filling there should be a full bottle inspector detectingglass particles in bottles or possible leakage (37)
Bottle Pasteurization (CCP11)
Pasteurization is carried out to ensure the beer shelf life over a period ofmonths This is accomplished by the development of tunnel pasteurization in whichthe beer bottle is subjected to 60C for 20 min Over-pasteurization which causesoxidation and can adversely affect beer flavor (38) is a potential physical hazardFurthermore it is crucial to check the time-temperature procedure with adequatecorrective actions for assuring the production of a satisfactory product
Bottle Inspection (CCP12)
Bottle inspection after the pasteurization step is important to ensure that bottleshave not been damaged during the process (39) Should such a situation occur theequipment has to be standardized by the production engineer
Labeling and Standardization (CCP13)
Labeling of the package should comply with the requirements of the CodexGeneral for the labeling of prepackaged foods (40) This means that the name of theproduct shall be clearly declared there must be a list of ingredients in descendingorder of proportion no other fruit may be represented pictorially except those usedand ldquothe date of minimum durabilityrdquo will be declared by the month and year inuncoded numerical sequence
BottleCan Packaging (CCP14)
Bottles (cans) are packaged into paperboard boxes of various sizes accordingto the bottle or can dimensions The encountered hazards can be of physical natureconcerning the bottles (cans) condition during the procedure
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 15
Storage (CCP15)
The finished beer undergoes chemical microbiological and organoleptic anal-ysis to ensure that its properties are within its specification range A synoptical pre-sentation of the occurring hazards CCPs CLs and preventive corrective measuresis given in Table 1
SAKE
Introduction
Sake is a fermented liquor made from rice and coming in many varietiesdepending on the raw materials manufacturing process and process after brewing(41) According to the earliest records sake was originally brewed from rice thathad been chewed to reach saccharification followed by natural fermentation Sakebrewed this way was used as a sacred wine in the worship of the Shinto gods Thisassociation with religion Shintoism and Buddhism has caused a deep intertwiningof sake with the traditions and social customs of Japan Thus today sake is servedat ceremonies and celebrations of all kinds (42) Sake has the highest alcoholpercentage by volume of any fermented beverage In its natural undiluted state itmay contain a potent 20 ethanol compared to 3ndash5 for beer or 9ndash12 for winewhich may reach higher values for fortified wines (4344) The central brewersrsquounion divides sake into four basic flavor types on four axes of sweet sour bitterand umai The latter is another translatorrsquos nightmare which generally ends uptranslated as delicious According to position established along these axes sakeis considered to be of ldquomature typerdquo ldquofragrant typerdquo ldquolight and smooth typerdquo orldquofull-bodied typerdquo (Fig 3) However no set of criteria can adequately express themultiplicity of sensations that together create the flavor unique to any individualsake but there is a perceived need for terms which quickly and simply give thegeneral idea
Figure 3 Main flavor types for sake characterization (43)
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ORDER REPRINTS
16 KOURTIS AND ARVANITOYANNIS
Sake Main Production Stages
The main stages for sake production are schematically presented in Figure 4
Raw Materials (CCP1)
The main ingredients of Japanese sake are rice sake rice sake yeastand water The rice most suitable for sake should consist of large grains and shouldbe soft with a white part at its center due to coarse cell structure Rice should complywith the maximum residue limits for pesticides and insecticides established by theCodex Alimentarius Commission for this commodity (45) (CCP chemical hazard)For Japanese sake yellow koji mold (Aspergillus oryzae) is used Sake yeast (Sac-charomyces cerevisiae) is a microbe converting the occurring glucose and mineralsin rice and water into alcohol Employment of bubble-free type yeast eliminates
Figure 4 Process flow diagram of sake production (264647)
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 17
the bubble removal step thus shortening the brewing period and reducing the costShould the factory wish to employ a specific yeast an adequate disinfection ofthe building interior is required otherwise undesirable bacteria may be introducedwhich could prove hazardous to human health (CCP microbiological hazard) (46)
Rice Polishing (CCP2)
The brown rice used for sake production must be first polished to remove theouter portion of the grain which contains fats proteins minerals and amino acidsthat can cause unpleasant flavors leaving the starch residues that are located in thecenter of the grain Nowadays machines are programmed to automatically removewhatever portion of the rice is required for the specific sake (47) The rice polishingratio (73ndash35) is expressed by the following formula (43)
Rice polishing ratio=(weight of white riceweight of brown rice)times100 (1)
The polishing process should be gently carried out because friction results inheat generation thereby greatly affecting water absorption and rice grain structureBroken grains are unlikely to satisfactorily ferment (47) Maybe the most importantstage in sake production consists of yeast starter mash production which can takeplace either with the classical Kimoto or slightly revised Yamahai process or withthe new ldquohigh speedrdquo methods (48)
Washing (CCP3)
After the rice has been polished rice powder clinging to the grain surface isremoved by washing Washing can be carried out either mechanically or manually(laborious hand washing) and should result in removing most of the organic andinorganic impurities reaching the CLs set by Codex Alimentarius of 15 and01 mm respectively
Soaking (Steeping)
Soaking allows rice to absorb the desired amount of water that is crucial toestablishing the rice consistency For sake produced ldquoen masserdquo simply dumpinginto a vat overnight for as long as 14 h is a usual case (47) However high polishedrice may be soaked within minutes In such a case an error of a minute might proveto have dire consequences for the end product (43)
Steaming (CCP4)
Steaming aims at softening the rice grains and breaking down the starchmolecules thus encouraging the growth of Aspergillus oryzae and eliminating all
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ORDER REPRINTS
18 KOURTIS AND ARVANITOYANNIS
other microorganisms leaving an initially sterile environment prone to sake moldpropagation Presence of lactic acid bacteria (LAB) and yeasts may occur at theend of this step representing a microbiological hazard and resulting in consider-able organoleptic losses The time can vary from 20 to 60 min depending on thebrewer and apparatus employed (40ndash60 and 20 min for traditional and automatedrespectively) (4346)
Cooling
The ensuing division of steamed rice is mainly related to its further use Apart of it is directly cooled by air blower whereas 20ndash30 is transferred to a heatedculture room to be infected with bacteria spores (Aspergillus oryzae) for sake moldproduction
Koji
Since rice grains contain no sugar it is the action of koji mold that converts thestarch in the grains to sugar The steamed rice is first cooled to 15ndash36C before beingtransferred to the koji culture room (30C) Spores of the mold are sprinkled likefine dust on the rice when it has cooled down to 33C After the spores are kneadedinto the steamed rice the rice is heaped and wrapped in cloths to prevent heat andmoisture loss which are two crucial factors for satisfactory bacterial growth Tomaintain uniform temperature and moisture rice is spread and mixed twice the firsttime after 20 hours (upon the appearance of white flecks) and then 7ndash8 h thereafteraccompanied by a distinctive aroma release (48)
Main Mash (Moromi) and Fermentation (CCP5)
In fermentation the occurring chemical hazards are related to heavy metalspresence (As lt 02 Cd lt 001 Pb lt 03 mgL) pesticide residues (as mentionedin Codex Alimentarius) and residues of detergents (absence) and ethylene glycole(absence) Their CLs can be determined and monitored with specific chemicalanalyses The ingredients of main mash (water koji rice and steamed rice) areadded to the starter mash in three steps (moving from small to bigger recipient)over a period of 4 days at successively lower temperatures thus preventing thegrowth of airborne bacteria (Table 2) A day after the addition of all the ingredientsformation of a moist surface showing clear cracks occurs Furthermore the mashbegins to bubble (indication of fermentation progress) as gas is given off during theburgeoning fermentation The fermentation can take place at various temperaturesand its duration depends on it that is at lower temperatures it takes up to twoweeks but the sake aroma is much more appealing compared to that formed athigher temperatures The characteristic sake aroma results from combined flavor
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 19
Table 2 Quantities of Ingredients at Each Stage of Mixing the Main Mash (Moromi)
Yeast 1st 2nd 3rd 4thStarter (Moto) Addition Addition Addition Additiona Total
Total rice (kg) 210 470 850 1470 3000Steamed rice (kg) 140 330 650 1230 2350Koji rice (kg) 70 140 200 240 65030 Brewerrsquos 1200 1200
alcohol (L)Water (L) 230 420 1010 2030 360 405
aTraditional brewers mix the final mash in three stages The fourth addition of alcohol and wateris a controversial postwar development (Kondo 1984)
components of a number of compounds produced during fermentation (49) Theelevated alcohol content of the fermented sake is related to lipid metabolism ofyeast in the presence of proteolipid provided by the koji molds (5051)
Additions (CCP6)
The addition of alcohol at this stage is carried out unless it is clearly statedthat sake does not contain any alcohol from extraneous sources The added alcoholshould not contain methanol or if it does the content of the latter should be lessthan 05 gL because of its toxicity (CCP chemical hazard)
Pressing
Automatic machine presses (consisting of a series of panels with balloon-likesacks attached) are most widely used nowadays instead of the traditional time-consuming method using long bags The remained caked lees are employed forpickle production and cooking or sedimentation of rice particles may occur Alter-natively sedimentation of rice particles at the bottom of the tank may take place
Filtration
Coloring and aging (maturation) inhibition can be effected by using activatedcharcoal filters
Pasteurization (CCP7 and CCP8)
Heating sake preferably twice at 65C kills off the remaining yeast stops en-zyme action and deactivates the lactic acid bacteria that will eventually spoil sakeThis process represents a microbiological hazard for which the specific plant may
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ORDER REPRINTS
20 KOURTIS AND ARVANITOYANNIS
set CLs However in recent years refrigerated storage and transport have madeunpasteurized sake with characteristic aroma available to the consumer (43)
Dilution
The produced sake in its raw state (Genchu) contains more than 20 alcoholby volume but it is generally diluted to about 15ndash16 vol-
BottlingStorageDistribution
The applied procedures are similar to those mentioned for the beer productionA summary of the occurring hazards CCPs CLs and preventive and correc-
tive measures is given in Table 3
WINE
Introduction
Wines are made from the fruit of Vitis vinifera of which there are a greatnumber of varieties growing in many parts of the world The history of wine isinextricably interwoven with human history It might be as true to say that it waswith wine that civilization began for the vine takes longer to mature than any othercrop and does not produce grapes for wine making until its fourth year It is notexactly known when men first had wine but it was accepted as a gift from the godsthe Egyptians attributed it to Osiris and the Greeks to Dionysos Mesopotamia andthe Caucasian slopes were no doubt early sources of wine from where it was spreadto Egypt and Greece and then to the rest of the world (52)
Wine Main Production Stages
The main stages for wine production are schematically presented in Figure 5
Harvesting (CCP1)
Grape harvesting is a CCP comprising both physical and chemical hazardsPhysically the grapes should be sound without rotten parts otherwise oxidativeand microbial contamination can rapidly develop Therefore harvesting shouldbe conducted with the greatest possible care and an efficient disease managementsystem should be applied (5354) Pesticides play an important role in pest man-agement but they should be handled with care because they constitute chemicalhazards (55) At the time of harvest the grapes must have also reached the correctmaturity when Brix and Total Acidity (TA) levels indicate maturity of wine Sincepesticide and fungicide residues on the surface of the berries constitute chemical
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 21
hazards Oliva et al (56) proposed a rapid and simple gas chromatographic methodfor their determination The maximum residue limits for pesticides in grapes andwines are provided by Codex Alimentarius (45) and Organisation International duVin (57) Finally the bulk bins used for grapes transportation should be effectivelydecontaminated to avoid any microbial infection
Stemming
Stemming includes the removal of stem leaves and grape stalks before crush-ing This procedure has several advantages because the total volume of processedproduct drops by 30 thus resulting in smaller tanks and eventually increasingthe productrsquos alcoholic content (58) However the end of fermentation and the al-cohol content of finished product depend mostly on the Brix level of initial grapesStemmers usually contain a perforated cylinder allowing berries to pass throughbut prevent the passage of stems stalks and leaves
Crushing
Crushing typically immediately follows stemming since some crushing ofthe fruit occurs during stemming The released juice is highly susceptible to oxida-tive browning and microbial contamination The most common crushing processesinvolve pressing the fruit against a perforated wall or passing the fruit through a setof rollers It is very important to avoid crushing the seeds to preclude contaminat-ing the must with seed oils the oxidation of which could produce rancid odors andconstitute an undesirable source of bitter tannins Equally important is the properhandling of product because inappropriate timing might lead to a sudden startof alcoholic fermentation and consequently to higher fermentation temperatureswhile a delay might cause microbial contamination and oxidative browning (59)
Maceration
Maceration is the breakdown of grape solids after crushing of grapes Whilemaceration is always involved in the initial stage of red wine fermentation the long-standing trend has been to limit maceration in white wine production Temperatureand duration of maceration depend on grape and wine variety Usually for white androse wines the maceration time is less than 24 h red destined for early consumptionis macerated for 3ndash5 days and red for aging is macerated from 5 days to 3 weeksFermentation usually occurs during this or at the end of maceration The amount ofthe antimicrobial to be used usually added to white musts that are most sensitive tooxidation depends on the crop health and maceration temperature Sulfur dioxidehas a distinct advantage over other antimicrobial agents because of the relativeinsensitivity of the wine yeasts to its action However it is also toxic or inhibitoryto most bacteria and yeasts (ie Candida Pichia Hansenula) at low concentrations(60) and has a rather low retention capability after the clarification step (61)
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ORDER REPRINTS
22 KOURTIS AND ARVANITOYANNISTa
ble
3Su
mm
ary
ofH
azar
dsC
CPs
CL
sM
onito
ring
Cor
rect
ive
Act
ions
and
Pers
onne
lRes
pons
ible
for
Sake
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
a(M
CP
)bM
easu
res
CC
PPa
ram
eter
(CL
s)Pr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
CC
ertifi
edsu
pplie
rs
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
wat
er
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Cer
tified
supp
liers
Hea
vym
etal
spr
esen
cein
wat
er
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Eva
luat
ion
ofth
ede
cont
amin
atin
gm
etho
ds
MC
ertifi
edsu
pplie
rs
prop
erpr
epar
atio
n
Mic
robi
alco
ntam
inat
ion
ofth
ecu
lture
100
clea
nM
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Wat
erm
icro
biol
ogic
alqu
ality
Abs
ence
ofpa
thog
ens
Insp
ectio
nof
the
equi
pmen
t
Ric
epo
lishi
ng(C
CP2
)C
Cer
tified
supp
lier
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
polis
hed
rice
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Was
hing
(CC
P3)
PC
ertifi
edsu
pplie
rs
inst
alla
tion
ofau
tom
atic
sepa
rato
r
Ani
mal
impu
ritie
sO
ther
orga
nic
and
inor
gani
cm
ater
01
mm
15
mm
01
mm
Spec
ific
exam
inat
ion
Rew
ashi
ngof
spec
ific
batc
hch
ange
supp
lier
Qua
lity
cont
rol
man
ager
Stea
min
g(f
orun
past
euri
sed
sake
)(C
CP4
)
MG
MP
sche
dule
dm
icro
biol
ogic
alco
ntro
ls
Pres
ence
ofye
asts
and
LA
B
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Spec
ific
batc
hre
proc
essi
ng
CIP
stan
dar-
disa
tion
Qua
lity
cont
rol
man
ager
T
rain
ned
pers
onne
l
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 23
Ferm
enta
tion
(CC
P5)
CM
ater
ialc
ontr
ol
GM
Pco
rros
ion
chec
ks
Hea
vym
etal
pres
ence
Pest
icid
ere
sidu
es
Aslt
02
Cd
lt
001
Pb
lt
03
(mg
L)
Spec
ific
chem
ical
anal
ysis
Dem
etal
lisat
ion
Cha
nge
supp
lier
Rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
GM
Pus
eof
nont
oxic
glyc
ole
Res
idue
sof
ehty
lene
glyc
ole
ampde
terg
ents
0Sp
ecifi
cch
emic
alan
alys
isD
ilutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Alc
ohol
addi
tion
(CC
P6)
CC
ertifi
edsu
pplie
rM
etha
nolc
onte
ntlt
05
gL
GC
exam
inat
ion
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erPa
steu
riza
tion
(CC
P7amp
CC
P8)
MR
unni
ngof
past
euri
ser
acco
rdin
gto
prog
ram
Det
ectio
nof
yeas
tsL
AB
en
zym
atic
activ
ity
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Tem
pera
ture
adju
stm
ent
batc
hre
proc
essi
ng
prop
erm
achi
nery
disi
nfec
tion
Qua
lity
cont
rol
man
ager
Tech
nica
lm
anag
er
aR
egar
ding
the
proc
edur
esof
bottl
ing
stor
age
and
dist
ribu
tion
the
CC
Psar
esi
mila
rto
thos
em
entio
ned
inTa
ble
1fo
rbe
erpr
oduc
tion
bM
CP
stan
dfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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2011
ORDER REPRINTS
24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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2011
ORDER REPRINTS
26 KOURTIS AND ARVANITOYANNIS
Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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2011
ORDER REPRINTS
28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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2011
ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
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ded
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] at
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ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
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itesi
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 3
Figure 1 HACCP decision tree (102)
for ordinary beer up to 15 Beerrsquos first production in Mesopotamia by the Sume-rians in the 5th millennium BC classifies it among the most ancient of alcoholicbeverages Towards the middle of the 3rd millennium BC there is documentary evi-dence of beer drinking by the Egyptians who probably introduced beer technology
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4 KOURTIS AND ARVANITOYANNIS
in Europe Beer drinking in northern Europe dates back to early antiquity contraryto the Mediterranean countries in which wine was the commonest drink A criticalpoint in its history was the works of Louis Pasteur which greatly contributed to theunderstanding of beer production (12)
Beer Main Production Stages
The main stages for beer production are shown schematically in Figure 2together with their critical control point (CCP) numbers
Incoming Raw Materials (CCP1)
The principal raw materials used to brew beer are water malted barley hopsand yeast Barley is required to be of sufficiently good malting quality in order togerminate and to produce a satisfactory product yield Other factors such as dor-mancy and losses during malting have also to be considered (13) The malting orsubsequent brewing characteristics are subtly affected by the weather conditionsprevailing over the growing period Some information regarding the quality of abatch of barley can be obtained by visual inspection but usually it is complementedby analyses including moisture content total nitrogen 1000-grain weight and theportion of nongerminating grain The National Institute of Agricultural Botany(UK) provides descriptions of the European malting varieties Residues of certainpesticides used on malting barley survive through to the final malt and wort and canaffect the process and quality of the end product (CCP) Fungicides and herbicidesinfluencing enzyme synthesis during malting process can accumulate in the yeastthereby affecting the next fermentation (14) The critical limits of these substancesare prescribed by Codex Alimentarius and are presented in Table 1 Presence ofheavy metals above the specifications of Directive 80776EC and mycotoxin pro-duction more than 004 mgL mainly from Fusarium species such as aflatoxinsochratoxine A zearoleon deoxyniralenol constitutes a high risk for human health(CCP) (15) Temperature and relative humidity are two interacting parameters thatdefine the germination of spores of different microorganisms (16) Visual inspec-tion and biological plate methods detect the fungal contamination for mycotoxinanalysis employment of HPLC or ELISA is required (17)
The quality of the water used is a major factor affecting the beer quality(CCP) The development of strict water control standards was introduced by mostbreweries in which water is filtered through activated carbon as well as ion ex-change resins to remove impurities (pesticides herbicides and industrial wastes)Two ions of particular importance in water are calcium and carbonatebicarbonatewhich control the pH during brewing Calcium also protects α-amylase from heatdestruction thereby permitting liquefaction of starch during mashing (18)
Hops not only provide bitter flavor to the beer but impart a hoppy characteras well These aroma components are derived from the essential oil The brewing
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 5
Figure 2 Process flow diagram of beer production (2226)
value of hops depends on the resin fraction which amounts to 15 and the essentialoil comprising sim05 Total resin is defined as the material soluble in both coldmethanol and diethyl ether ldquosoftrdquo resin is that proportion of the total which issoluble in hexane comprising mainly α and β-acids while ldquohardrdquo resin is insolublein hexane The α-acids that are the most significant bittering precursors can bedistinguished from other soft resins from their ability to form a lead salt which isinsoluble in methanol The determination of moisture and seed content also provideuseful conclusions about their quality (13) Adjuncts of carbohydrate origin other
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ORDER REPRINTS
6 KOURTIS AND ARVANITOYANNIS
Tabl
e1
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rB
eer
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Mon
itori
ngC
orre
ctiv
eR
espo
nsib
lePr
oces
sSt
ep(P
MC
)aM
easu
res
CC
PPa
ram
eter
Cri
tical
Lim
itPr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
fung
ide
velo
pmen
tte
mpe
ratu
rean
dR
Hre
gula
tion
duri
ngst
orag
e
Myc
otox
inpr
oduc
tion
000
4m
gL
Vis
uali
nspe
ctio
nof
fung
ide
velo
pmen
tH
PLC
EL
ISA
E
PSan
alys
is
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
er
Cer
tified
supp
liers
sc
hedu
lein
spec
tions
Pres
ence
ofE
nter
o-ba
cter
iace
ae
0M
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Cha
nge
supp
lier
Stri
cktly
follo
win
gin
stru
ctio
nsC
onta
min
atio
nof
mic
robi
alpr
epar
atio
ns
100
clea
nC
hang
epr
epar
atio
nm
etho
dC
Effi
cien
tdis
ease
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
barl
eyh
ops
wat
er
By
pest
icid
eas
desc
ribe
dby
Cod
ex
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erC
ertifi
edsu
pplie
rsPr
oper
wat
erde
cont
amin
atio
nH
eavy
met
als
pres
ence
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Rej
ectio
nof
spec
ific
batc
hD
e-m
etal
lisat
ion
step
Use
ofde
ioni
ser
Wat
errsquos
elec
tric
alco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nise
r
Aut
omat
icdi
scon
tinua
tion
ofde
ioni
ser
anal
ysis
ofw
ater
sam
ples
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 7
Mal
ting
(CC
P2)
CU
seof
indi
rect
heat
ing
syst
ems
cont
roll
ow-N
Ox
burn
ers
ND
MA
prod
uctio
ndu
ring
kiln
ing
25
ppb
Con
tinuo
usch
ecki
ngth
ear
eas
peci
fican
alys
es
Rej
ectio
nor
mix
ing
with
othe
rba
tche
s
Qua
lity
cont
rol
man
ager
PC
ontr
olof
time
tem
pera
ture
and
RH
Col
our
and
flavo
urde
velo
pmen
tSp
ecifi
edby
part
icul
arpl
ant
Con
tinuo
usm
onito
ring
ofpr
oces
sing
cond
ition
s
Mix
ing
with
othe
rm
alts
rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
MPr
oper
hadl
ing
oper
atio
nsaf
ter
prod
uctio
n
Myc
otox
inpr
oduc
tion
000
4m
gL
Vis
uali
nspe
ctio
nof
fung
ide
velo
pmen
tH
PLC
EL
ISA
E
PSan
alys
is
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
er
Mas
hing
(CC
P3)
CC
ontr
olof
tem
pera
ture
CIP
ND
MA
prod
uctio
nde
terg
ent
resi
dues
25
ppb
Non
eC
ontin
uous
reco
rdin
gof
the
proc
essi
ng
Adj
ustl
aute
ring
prog
ram
Qua
lity
cont
rol
man
ager
Lau
teri
ng(C
CP4
)C
Sche
dule
Insp
ectio
nun
der
plat
ecl
eani
ng
AT
NC
lt20
ppb
Mic
robi
olog
ical
and
chem
ical
anal
yses
Prop
erm
aint
ain
re-l
aute
ring
ofth
eba
tch
Qua
lity
cont
rol
man
ager
Boi
ling
(CC
P5)
CC
orre
ctus
eof
boile
rtr
eatm
ent
chem
ical
s
Con
tam
inat
ion
with
dete
rgen
ts0
CIP
syst
emR
epai
rC
IPb
atch
reje
ctio
nQ
ualit
yco
ntro
lm
anag
erFe
rmen
tatio
n(C
CP6
)M
Aer
atio
nof
wor
tus
eof
yeas
tfor
max
6ge
nera
tions
Poor
yeas
tvi
abili
tyldquo
stuc
krdquofe
rmen
tatio
n
Min
90
viab
leye
astc
ell
Yea
stco
ncen
trat
ion
ferm
enta
bilit
yO
2co
ncen
trat
ion
inth
ew
ort
Incr
ease
prop
agat
ion
freq
uenc
yw
ort
aera
tion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
8 KOURTIS AND ARVANITOYANNIS
Tabl
e1
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Mon
itori
ngC
orre
ctiv
eR
espo
nsib
lePr
oces
sSt
ep(P
MC
)aM
easu
res
CC
PPa
ram
eter
Cri
tical
Lim
itPr
oced
ures
Act
ions
Pers
onne
l
Ferm
enta
tion
(CC
P6)
MIn
spec
tion
ofC
IPsy
stem
and
equi
pmen
t
Lac
toba
cill
iac
etic
acid
bact
eria
and
wil
dye
asts
Pres
ence
in1
mL
plat
e+1
mL
actid
ione
Plat
eco
unt
met
hod
ora
rapi
dde
tect
ion
met
hod
Prop
erdi
sinf
ectio
nof
equi
pmen
tre
proc
essi
ngof
the
batc
h
Qua
lity
cont
rol
man
ager
Filtr
atio
n(C
CP7
)C
Use
CO
2
prefi
lling
offil
ter
with
wat
er
O2
upta
kegt
02
ppm
diss
olve
dO
2
Mea
sure
men
tof
diss
olve
dO
2
Surv
eyof
filtr
atio
nfo
rin
crea
sed
O2
pick
up
Qua
lity
cont
rol
man
ager
Bot
tlec
anin
spec
tor
(CC
P8)
CG
MP
Cle
anin
gpe
rfor
man
ceN
oso
lids
noliq
uid
rem
nant
sE
labo
rate
elec
tron
icre
cogn
ition
syst
ems
afte
rC
IP
Rew
ashi
ngof
bottl
esC
IPsy
stem
insp
ectio
n
Qua
lity
cont
rol
man
ager
PC
ertifi
edsu
pplie
rpr
oper
hand
ling
ofbo
ttles
Bot
tles
prop
erfo
rfo
ods
and
drin
ks
bottl
esco
nditi
on
Cra
cks
scra
tche
sab
senc
eO
n-lin
evi
sual
cont
rol
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlec
anfil
ler
(CC
P9)
CIn
stal
latio
nof
cont
rolli
ngeq
uipm
ento
nth
eC
IPsy
stem
Con
tam
inat
ion
with
dete
rgen
tsC
ompl
ete
abse
nce
Org
anol
eptic
exam
inat
ion
offil
led
bottl
es
Bat
chre
ject
ion
Tra
ined
pers
onne
l
Bot
tlec
anse
aler
(CC
P10)
PC
orre
ctin
stal
latio
nof
equi
pmen
tB
low
-off
effe
ctO
ccur
renc
ere
duce
dto
anac
cept
able
leve
l
Con
trol
sets
ealin
gpr
essu
reA
utom
atic
rem
oval
ofde
stro
yed
bottl
es
Tra
ined
pers
onne
l
Bot
tlec
anpa
steu
riza
tion
(CC
P11)
PR
unni
ngpa
steu
rise
rac
cord
ing
topr
ogra
m
Oxi
datio
nca
used
ofw
rong
tem
pera
ture
-tim
ese
t
Max
65 C
for
20m
inq
uick
cool
ing
atth
eex
it
Con
tinuo
uson
-lin
etim
e-te
mpe
ratu
rech
ecki
ng
Adj
ust
tem
pera
ture
m
aint
ain
equi
pmen
t
Tech
nica
lm
anag
er
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 9
Bot
tlec
anin
spec
tion
(CC
P12)
PR
egul
arin
spec
tion
ofth
em
achi
nery
Phys
ical
dam
age
Occ
urre
nce
redu
ced
toan
acce
ptab
lele
vel
On-
line
mon
itori
ngE
quip
men
tst
anda
rdis
atio
nTe
chni
cal
man
ager
Lab
elin
g(C
CP1
3)P
Car
eful
sele
ctio
nof
the
etiq
uette
sM
ispl
aced
etiq
uette
sR
educ
edto
anac
cept
able
leve
lV
isua
lche
cks
cont
rolo
fth
eeq
uipm
ent
Rel
abel
ing
the
spec
ific
batc
hT
rain
edpe
rson
nel
Bot
tlec
anpa
ckag
ing
(CC
P14)
PC
orre
ctin
stal
latio
nof
the
equi
pmen
tB
ottle
sco
nditi
ondu
ring
palle
tisat
ion
Abs
ence
ofri
fts
inth
elu
tec
rack
orsc
ratc
hes
On-
line
visu
alco
ntro
lA
djus
tthe
equi
pmen
tpa
ram
eter
s(s
peed
pre
ssur
e)
Tech
nica
lm
anag
er
Stor
age
(CC
P15)
PC
ontr
olst
orag
eco
nditi
ons
Org
anol
eptic
cond
ition
ofbe
erSp
ecifi
edby
the
part
icul
arpl
ant
Sche
dule
dco
ntro
lsof
finis
hed
prod
uct
Adj
ustt
hest
oreh
ouse
cond
ition
s
Tra
ined
pers
onne
l
aP
MC
stan
dfo
rph
ysic
alm
icro
biol
ogic
alan
dch
emic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
10 KOURTIS AND ARVANITOYANNIS
than malt are sometimes used as an additional source of extract to supplementmalt Unmalted cereal adjuncts usually contain no active enzymes and thereforerely on malt or exogenous enzymes to provide the necessary enzymes for starchconversion (19)
Yeast growth cannot be separated from the fermentation process and it isnecessary to the production of both beer and fresh yeast for use in subsequentfermentations The quality control of yeasts comprises a) the selection maintenanceand supply of a suitable strain and b) the routine assessment of purity and detectionof microbial contamination (CCP) (20)
Malting (CCP2)
This process involves steeping the barley in a shallow bed of water at a tem-perature of 10ndash15C so that its moisture content amounts to 45 wt- of barleyBarley is then allowed to germinate under controlled temperature conditions atapproximately 15C and RH100 with constant turning to prevent matting therootlets The barleycorn undergoes germination through air passage via the germi-nating malt for 3ndash5 days Gentle heating stops germination due to moisture removaland promotes formation of flavor compounds The kiln temperature regime is cru-cial for the color of malt and the survival of enzymes to be used in the mashingprocess Kilning duration usually varies between 24 and 48 h Time temperatureand moisture content are varied to control color and flavor development Chemicalmicrobiological and physical hazards may be encountered in this step In partic-ular nitrosodimethylamine (NDMA) production during kilning (reaction of NOx
with organic materials) constitutes a chemical hazard with a critical limit (CL) at25 ppb because of its suspected carcinogenic effect In addition mycotoxin pro-duction more than 0004 mgL and color and flavor alteration represent chemicaland physical hazards respectively The NDMA content in malt can be controlled byusing indirect heating systems or by carefully maintained and controlled low-NOx
burners Regular checks should nevertheless be carried out by the maltster so thatthe residual risk caused by polluted air is kept as low as possible (17) The finishedmalt has its rootlets removed and is screened to produce the uniform quality Duringthe malting process two important changes occur a) the barley develops its ownenzyme systems and b) the naturally produced enzymes start to break down the cellstructure of the endosperm (19) Malt quality control tests include hot water extractcolor soluble nitrogen total nitrogen moisture enzyme activities viscosity andlautering prediction tests The microbiological status of malt used in the followingsteps (CCP) is very much dependent on its handling operations after production (16)
Milling
The main function of dry or wet milling is to reduce the malt particle sizeto form grist (ground or milled grain) The particle size reduction facilitates the
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 11
extraction of soluble components mainly sugars and nitrogenous compounds fromthe endosperm (21)
Mashing (CCP3)
Mashing the first step in wort production involves extracting soluble materi-als from the milled malt This is accomplished by feeding the grist through Steelrsquosmasher a hydrator consisting of a large-bore tube bent at right angles During itspassage through the vertical portion of tube the grist is spayed with hot water (typ-ically 65C) and then mixed with the help of a revolving screw (22) The floatingendosperm particles hydrate and undergo further amylolytic scission by α- andβ-amylases Processors adjust the pH and temperature conditions to allow bothenzymes with a range of susceptibility to pH and temperature to work effectivelyNDMA production (CL = 25 ppb) as well as possible detergent residues constitutepotential chemical hazards for public health Continuous monitoring at the process-ing and adjustment of the lautering program and Cleaning In Place (CIP) systemwhen deviation occurs are proper preventive and corrective actions respectively
Lautering (CCP4)
The lauter tun is a vessel normally rinsed thoroughly with a sparging or hotwater delivery system before receiving the mash which precipitates at the flat floorof slotted stainless steel or brass plates At tun center there is a lautering machineon the shaft of which rotating rakes are attached to facilitate draining the wortinto a collection vessel called grant The wort is recirculated through the lauter tununtil it reaches a certain degree of clarity whereupon it is delivered to the kettle(21) In lautering production of Apparent Total N-nitroso compounds (ATNC)above the CL of 20 ppb constitute a CCP that should be monitored with chemicaland microbiological analyses Scheduled inspection and under-plate cleaning canprevent insufficient separation of trub from wort (23)
Boiling (CCP5)
Wort is boiled for up to 2 h at atmospheric pressure following the additionof hops (CCP) The shape of copper boiling time and temperature can affect thequality of produced beer The major objectives of wort boiling are a) wort steril-ization and enzyme inactivation b) extraction of bitter and other substances fromhops and formation of flavor compounds and c) evaporation of excess water andwort concentration evaporation of undesirable flavour volatiles Wort contamina-tion of the wort with Enterobacteriaceae from hops can result in various off-flavorsincluding ldquovegetablerdquo and ldquophenolicrdquo taints (24) Correct use of boiler treatmentchemicals steam condensate tasting for carrying over the taints and operation of
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ORDER REPRINTS
12 KOURTIS AND ARVANITOYANNIS
phenol analyses are all essential to avoid chemical contamination and taints devel-opment (23)
Clarification
Wort clarification is conducted either through sedimentation or filtrationWhen whole hop cones are used it is necessary to employ either a hop back ora hop separatorndashfilter The drop in hop usage and the widespread acceptance ofpreisomerized extracts led to utilization of a vertical cylinder known as whirlpoolwhich induces sustainable circulation of the trub collecting as a compact cone in thebase Whirlpools are more suited to larger worts and can also be used with ale Inmodern breweries centrifuges constitute a promising alternative to whirlpools (25)
Cooling
To prepare for fermentation the clear hopped wort is cooled usually in aplate heat exchanger During cooling it is advisable to aerate or even to oxygenatethe wort because next processing step involves yeast growth promoted in the pres-ence of dissolved oxygen despite the low dissolved oxygen concentration in wort(7ndash14 ppm) (22)
Fermentation (CCP6)
Fermentation aims at producing ethanol by fermenting yeasts Yeasts vary intheir behavior during fermentation some strains tend to flocculate trap plug CO2 andrising to the top whereas others do not flocculate and precipitate Several lagers areproduced by bottom fermentation while many types of ales and stouts are producedby top fermentation Saccharomyces cerevisiae is usually the top fermenting yeastin the range of 18ndash22C whilst the bottom-fermenting are strains of Saccharomycesuvarum that function in the range of 7ndash15C (26) Therefore the temperature atwhich fermentation occurs is very crucial for the further stages of beer productionThe modern use of cylindroconical vessels has reduced the fermentation periodfor ales and lagers from 7 to 2 or 3 days and from 10 to 7 days respectively (27)Fermentation is monitored by taking samples for measuring the specific gravityand can be controlled by varying the cooling rate (20) ldquoStuckrdquo fermentation wherethe required ethanol level is not attained and microbial contamination with Lacticacid bacteria mainly Lactobacilii and Pediococcus which cause taints duringmaturation or in bottle storage (28) represent microbiological hazards which arethe only hazard detected at this stage Common causes for ldquostuckrdquo fermentationinclude premature yeast flocculation and yeast failure to metabolize maltotriosedue to repression by glucose (25) A minimum of 90 viable yeast cells (CL) canbe applied to ensure the development of the process During fermentation the pH
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 13
drops from 52 to 42 and by its completion the yeast is removed either as a top orbottom crop and retained to pitch the next fermentation Apart from the conventionalmicrobial detection methods with plate count several rapid detection methodspotentially applied in breweries such as ATP bioluminescence flow cytometryand polymerase chain reaction have been developed to reduce the incubation timefrom 3ndash4 days to 1ndash2 (2930)
Maturation
Maturation includes all those changes occurring between the end of primaryfermentation to beer filtration (31) Ale is matured at relatively warm temperatures12ndash20C while lagers are held under much cooler conditions The warmer temper-atures allow the rapid metabolism of any residual and priming sugars as well asloss of green flavors within 1ndash2 weeks depending on beer type yeast strain wortcomposition and primary fermentation conditions In case of lager the beer used tobe held at refrigerated temperatures for up to several months after fermentation al-lowing formation of proteintannin complexes (18) Today the enzyme addition hassubstantially shortened this process to several weeks during which flavor maturesEnzymes such as papain may be added during transfer between fermentation andmaturation tank The dosage of the proteolytic enzyme varies depending on typeof beer and process Enzyme activity decreases progressively during maturationuntil its inactivation with pasteurization Part of the enzyme absorbed in the yeastsurface is removed during filtration (19)
Filtration (CCP7)
Beer produced during fermentation is turbid and should be clarified prior to itsmarketing This turbidity is due to the presence of yeasts and proteinaceous materi-als associated with carbohydrates and polyphenols The formation of these proteinprecipitates is attributed to cold temperature low pH and poor solubility in alcoholicsolutions (32) To prevent this from occurring in the final product the beer may besubjected to various chill-proofing treatments during its storage These treatmentsgenerally include the addition of clays to absorb the colloidal materials or prote-olytic enzymes used to further solubilize the protein fraction (33) Since oxygenuptake during this process could severely affect the product organoleptic charac-teristics a CCP of dissolved oxygen should be applied with a CL of 02 ppm (34)
Packaging and Sealing
The packing section comprises several CCPs including the containers to beused their cleaning and disinfection (CCP8) the filler line (CCP9) and the sealer(CCP10) The bursting pressure of the bottles as guaranteed by the manufacturerin his specifications for the new glass may no longer be valid in case of reusable
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ORDER REPRINTS
14 KOURTIS AND ARVANITOYANNIS
bottles due to the considerable physical stress during already exerted upon themduring the filling process Insufficient cleaning of reusable bottles due to low temper-atures and concentrations of the employed cleaning solutions as well as presence ofextraneous entrapped materials within bottles and improper emptying consist pos-sible hazards Moreover cleaning solution remnants and shards introduced throughthe procedure pose problems under working conditions The beer filler may be con-taminated by cleaning and disinfection solutions Contamination sources may bedue to inadequate pressure or faulty CIP system resulting in cleaning and disinfect-ing solution remains in the pressure tank or the ring bowl of the filler (3536) Thecrown corker should be correctly installed the filling pressure of bottle caps on themouths of the bottles should be adjusted to ensure a specified blow-off effect toavoid bottle bursting After filling there should be a full bottle inspector detectingglass particles in bottles or possible leakage (37)
Bottle Pasteurization (CCP11)
Pasteurization is carried out to ensure the beer shelf life over a period ofmonths This is accomplished by the development of tunnel pasteurization in whichthe beer bottle is subjected to 60C for 20 min Over-pasteurization which causesoxidation and can adversely affect beer flavor (38) is a potential physical hazardFurthermore it is crucial to check the time-temperature procedure with adequatecorrective actions for assuring the production of a satisfactory product
Bottle Inspection (CCP12)
Bottle inspection after the pasteurization step is important to ensure that bottleshave not been damaged during the process (39) Should such a situation occur theequipment has to be standardized by the production engineer
Labeling and Standardization (CCP13)
Labeling of the package should comply with the requirements of the CodexGeneral for the labeling of prepackaged foods (40) This means that the name of theproduct shall be clearly declared there must be a list of ingredients in descendingorder of proportion no other fruit may be represented pictorially except those usedand ldquothe date of minimum durabilityrdquo will be declared by the month and year inuncoded numerical sequence
BottleCan Packaging (CCP14)
Bottles (cans) are packaged into paperboard boxes of various sizes accordingto the bottle or can dimensions The encountered hazards can be of physical natureconcerning the bottles (cans) condition during the procedure
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 15
Storage (CCP15)
The finished beer undergoes chemical microbiological and organoleptic anal-ysis to ensure that its properties are within its specification range A synoptical pre-sentation of the occurring hazards CCPs CLs and preventive corrective measuresis given in Table 1
SAKE
Introduction
Sake is a fermented liquor made from rice and coming in many varietiesdepending on the raw materials manufacturing process and process after brewing(41) According to the earliest records sake was originally brewed from rice thathad been chewed to reach saccharification followed by natural fermentation Sakebrewed this way was used as a sacred wine in the worship of the Shinto gods Thisassociation with religion Shintoism and Buddhism has caused a deep intertwiningof sake with the traditions and social customs of Japan Thus today sake is servedat ceremonies and celebrations of all kinds (42) Sake has the highest alcoholpercentage by volume of any fermented beverage In its natural undiluted state itmay contain a potent 20 ethanol compared to 3ndash5 for beer or 9ndash12 for winewhich may reach higher values for fortified wines (4344) The central brewersrsquounion divides sake into four basic flavor types on four axes of sweet sour bitterand umai The latter is another translatorrsquos nightmare which generally ends uptranslated as delicious According to position established along these axes sakeis considered to be of ldquomature typerdquo ldquofragrant typerdquo ldquolight and smooth typerdquo orldquofull-bodied typerdquo (Fig 3) However no set of criteria can adequately express themultiplicity of sensations that together create the flavor unique to any individualsake but there is a perceived need for terms which quickly and simply give thegeneral idea
Figure 3 Main flavor types for sake characterization (43)
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ORDER REPRINTS
16 KOURTIS AND ARVANITOYANNIS
Sake Main Production Stages
The main stages for sake production are schematically presented in Figure 4
Raw Materials (CCP1)
The main ingredients of Japanese sake are rice sake rice sake yeastand water The rice most suitable for sake should consist of large grains and shouldbe soft with a white part at its center due to coarse cell structure Rice should complywith the maximum residue limits for pesticides and insecticides established by theCodex Alimentarius Commission for this commodity (45) (CCP chemical hazard)For Japanese sake yellow koji mold (Aspergillus oryzae) is used Sake yeast (Sac-charomyces cerevisiae) is a microbe converting the occurring glucose and mineralsin rice and water into alcohol Employment of bubble-free type yeast eliminates
Figure 4 Process flow diagram of sake production (264647)
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 17
the bubble removal step thus shortening the brewing period and reducing the costShould the factory wish to employ a specific yeast an adequate disinfection ofthe building interior is required otherwise undesirable bacteria may be introducedwhich could prove hazardous to human health (CCP microbiological hazard) (46)
Rice Polishing (CCP2)
The brown rice used for sake production must be first polished to remove theouter portion of the grain which contains fats proteins minerals and amino acidsthat can cause unpleasant flavors leaving the starch residues that are located in thecenter of the grain Nowadays machines are programmed to automatically removewhatever portion of the rice is required for the specific sake (47) The rice polishingratio (73ndash35) is expressed by the following formula (43)
Rice polishing ratio=(weight of white riceweight of brown rice)times100 (1)
The polishing process should be gently carried out because friction results inheat generation thereby greatly affecting water absorption and rice grain structureBroken grains are unlikely to satisfactorily ferment (47) Maybe the most importantstage in sake production consists of yeast starter mash production which can takeplace either with the classical Kimoto or slightly revised Yamahai process or withthe new ldquohigh speedrdquo methods (48)
Washing (CCP3)
After the rice has been polished rice powder clinging to the grain surface isremoved by washing Washing can be carried out either mechanically or manually(laborious hand washing) and should result in removing most of the organic andinorganic impurities reaching the CLs set by Codex Alimentarius of 15 and01 mm respectively
Soaking (Steeping)
Soaking allows rice to absorb the desired amount of water that is crucial toestablishing the rice consistency For sake produced ldquoen masserdquo simply dumpinginto a vat overnight for as long as 14 h is a usual case (47) However high polishedrice may be soaked within minutes In such a case an error of a minute might proveto have dire consequences for the end product (43)
Steaming (CCP4)
Steaming aims at softening the rice grains and breaking down the starchmolecules thus encouraging the growth of Aspergillus oryzae and eliminating all
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ORDER REPRINTS
18 KOURTIS AND ARVANITOYANNIS
other microorganisms leaving an initially sterile environment prone to sake moldpropagation Presence of lactic acid bacteria (LAB) and yeasts may occur at theend of this step representing a microbiological hazard and resulting in consider-able organoleptic losses The time can vary from 20 to 60 min depending on thebrewer and apparatus employed (40ndash60 and 20 min for traditional and automatedrespectively) (4346)
Cooling
The ensuing division of steamed rice is mainly related to its further use Apart of it is directly cooled by air blower whereas 20ndash30 is transferred to a heatedculture room to be infected with bacteria spores (Aspergillus oryzae) for sake moldproduction
Koji
Since rice grains contain no sugar it is the action of koji mold that converts thestarch in the grains to sugar The steamed rice is first cooled to 15ndash36C before beingtransferred to the koji culture room (30C) Spores of the mold are sprinkled likefine dust on the rice when it has cooled down to 33C After the spores are kneadedinto the steamed rice the rice is heaped and wrapped in cloths to prevent heat andmoisture loss which are two crucial factors for satisfactory bacterial growth Tomaintain uniform temperature and moisture rice is spread and mixed twice the firsttime after 20 hours (upon the appearance of white flecks) and then 7ndash8 h thereafteraccompanied by a distinctive aroma release (48)
Main Mash (Moromi) and Fermentation (CCP5)
In fermentation the occurring chemical hazards are related to heavy metalspresence (As lt 02 Cd lt 001 Pb lt 03 mgL) pesticide residues (as mentionedin Codex Alimentarius) and residues of detergents (absence) and ethylene glycole(absence) Their CLs can be determined and monitored with specific chemicalanalyses The ingredients of main mash (water koji rice and steamed rice) areadded to the starter mash in three steps (moving from small to bigger recipient)over a period of 4 days at successively lower temperatures thus preventing thegrowth of airborne bacteria (Table 2) A day after the addition of all the ingredientsformation of a moist surface showing clear cracks occurs Furthermore the mashbegins to bubble (indication of fermentation progress) as gas is given off during theburgeoning fermentation The fermentation can take place at various temperaturesand its duration depends on it that is at lower temperatures it takes up to twoweeks but the sake aroma is much more appealing compared to that formed athigher temperatures The characteristic sake aroma results from combined flavor
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 19
Table 2 Quantities of Ingredients at Each Stage of Mixing the Main Mash (Moromi)
Yeast 1st 2nd 3rd 4thStarter (Moto) Addition Addition Addition Additiona Total
Total rice (kg) 210 470 850 1470 3000Steamed rice (kg) 140 330 650 1230 2350Koji rice (kg) 70 140 200 240 65030 Brewerrsquos 1200 1200
alcohol (L)Water (L) 230 420 1010 2030 360 405
aTraditional brewers mix the final mash in three stages The fourth addition of alcohol and wateris a controversial postwar development (Kondo 1984)
components of a number of compounds produced during fermentation (49) Theelevated alcohol content of the fermented sake is related to lipid metabolism ofyeast in the presence of proteolipid provided by the koji molds (5051)
Additions (CCP6)
The addition of alcohol at this stage is carried out unless it is clearly statedthat sake does not contain any alcohol from extraneous sources The added alcoholshould not contain methanol or if it does the content of the latter should be lessthan 05 gL because of its toxicity (CCP chemical hazard)
Pressing
Automatic machine presses (consisting of a series of panels with balloon-likesacks attached) are most widely used nowadays instead of the traditional time-consuming method using long bags The remained caked lees are employed forpickle production and cooking or sedimentation of rice particles may occur Alter-natively sedimentation of rice particles at the bottom of the tank may take place
Filtration
Coloring and aging (maturation) inhibition can be effected by using activatedcharcoal filters
Pasteurization (CCP7 and CCP8)
Heating sake preferably twice at 65C kills off the remaining yeast stops en-zyme action and deactivates the lactic acid bacteria that will eventually spoil sakeThis process represents a microbiological hazard for which the specific plant may
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ORDER REPRINTS
20 KOURTIS AND ARVANITOYANNIS
set CLs However in recent years refrigerated storage and transport have madeunpasteurized sake with characteristic aroma available to the consumer (43)
Dilution
The produced sake in its raw state (Genchu) contains more than 20 alcoholby volume but it is generally diluted to about 15ndash16 vol-
BottlingStorageDistribution
The applied procedures are similar to those mentioned for the beer productionA summary of the occurring hazards CCPs CLs and preventive and correc-
tive measures is given in Table 3
WINE
Introduction
Wines are made from the fruit of Vitis vinifera of which there are a greatnumber of varieties growing in many parts of the world The history of wine isinextricably interwoven with human history It might be as true to say that it waswith wine that civilization began for the vine takes longer to mature than any othercrop and does not produce grapes for wine making until its fourth year It is notexactly known when men first had wine but it was accepted as a gift from the godsthe Egyptians attributed it to Osiris and the Greeks to Dionysos Mesopotamia andthe Caucasian slopes were no doubt early sources of wine from where it was spreadto Egypt and Greece and then to the rest of the world (52)
Wine Main Production Stages
The main stages for wine production are schematically presented in Figure 5
Harvesting (CCP1)
Grape harvesting is a CCP comprising both physical and chemical hazardsPhysically the grapes should be sound without rotten parts otherwise oxidativeand microbial contamination can rapidly develop Therefore harvesting shouldbe conducted with the greatest possible care and an efficient disease managementsystem should be applied (5354) Pesticides play an important role in pest man-agement but they should be handled with care because they constitute chemicalhazards (55) At the time of harvest the grapes must have also reached the correctmaturity when Brix and Total Acidity (TA) levels indicate maturity of wine Sincepesticide and fungicide residues on the surface of the berries constitute chemical
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 21
hazards Oliva et al (56) proposed a rapid and simple gas chromatographic methodfor their determination The maximum residue limits for pesticides in grapes andwines are provided by Codex Alimentarius (45) and Organisation International duVin (57) Finally the bulk bins used for grapes transportation should be effectivelydecontaminated to avoid any microbial infection
Stemming
Stemming includes the removal of stem leaves and grape stalks before crush-ing This procedure has several advantages because the total volume of processedproduct drops by 30 thus resulting in smaller tanks and eventually increasingthe productrsquos alcoholic content (58) However the end of fermentation and the al-cohol content of finished product depend mostly on the Brix level of initial grapesStemmers usually contain a perforated cylinder allowing berries to pass throughbut prevent the passage of stems stalks and leaves
Crushing
Crushing typically immediately follows stemming since some crushing ofthe fruit occurs during stemming The released juice is highly susceptible to oxida-tive browning and microbial contamination The most common crushing processesinvolve pressing the fruit against a perforated wall or passing the fruit through a setof rollers It is very important to avoid crushing the seeds to preclude contaminat-ing the must with seed oils the oxidation of which could produce rancid odors andconstitute an undesirable source of bitter tannins Equally important is the properhandling of product because inappropriate timing might lead to a sudden startof alcoholic fermentation and consequently to higher fermentation temperatureswhile a delay might cause microbial contamination and oxidative browning (59)
Maceration
Maceration is the breakdown of grape solids after crushing of grapes Whilemaceration is always involved in the initial stage of red wine fermentation the long-standing trend has been to limit maceration in white wine production Temperatureand duration of maceration depend on grape and wine variety Usually for white androse wines the maceration time is less than 24 h red destined for early consumptionis macerated for 3ndash5 days and red for aging is macerated from 5 days to 3 weeksFermentation usually occurs during this or at the end of maceration The amount ofthe antimicrobial to be used usually added to white musts that are most sensitive tooxidation depends on the crop health and maceration temperature Sulfur dioxidehas a distinct advantage over other antimicrobial agents because of the relativeinsensitivity of the wine yeasts to its action However it is also toxic or inhibitoryto most bacteria and yeasts (ie Candida Pichia Hansenula) at low concentrations(60) and has a rather low retention capability after the clarification step (61)
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ORDER REPRINTS
22 KOURTIS AND ARVANITOYANNISTa
ble
3Su
mm
ary
ofH
azar
dsC
CPs
CL
sM
onito
ring
Cor
rect
ive
Act
ions
and
Pers
onne
lRes
pons
ible
for
Sake
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
a(M
CP
)bM
easu
res
CC
PPa
ram
eter
(CL
s)Pr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
CC
ertifi
edsu
pplie
rs
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
wat
er
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Cer
tified
supp
liers
Hea
vym
etal
spr
esen
cein
wat
er
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Eva
luat
ion
ofth
ede
cont
amin
atin
gm
etho
ds
MC
ertifi
edsu
pplie
rs
prop
erpr
epar
atio
n
Mic
robi
alco
ntam
inat
ion
ofth
ecu
lture
100
clea
nM
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Wat
erm
icro
biol
ogic
alqu
ality
Abs
ence
ofpa
thog
ens
Insp
ectio
nof
the
equi
pmen
t
Ric
epo
lishi
ng(C
CP2
)C
Cer
tified
supp
lier
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
polis
hed
rice
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Was
hing
(CC
P3)
PC
ertifi
edsu
pplie
rs
inst
alla
tion
ofau
tom
atic
sepa
rato
r
Ani
mal
impu
ritie
sO
ther
orga
nic
and
inor
gani
cm
ater
01
mm
15
mm
01
mm
Spec
ific
exam
inat
ion
Rew
ashi
ngof
spec
ific
batc
hch
ange
supp
lier
Qua
lity
cont
rol
man
ager
Stea
min
g(f
orun
past
euri
sed
sake
)(C
CP4
)
MG
MP
sche
dule
dm
icro
biol
ogic
alco
ntro
ls
Pres
ence
ofye
asts
and
LA
B
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Spec
ific
batc
hre
proc
essi
ng
CIP
stan
dar-
disa
tion
Qua
lity
cont
rol
man
ager
T
rain
ned
pers
onne
l
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 23
Ferm
enta
tion
(CC
P5)
CM
ater
ialc
ontr
ol
GM
Pco
rros
ion
chec
ks
Hea
vym
etal
pres
ence
Pest
icid
ere
sidu
es
Aslt
02
Cd
lt
001
Pb
lt
03
(mg
L)
Spec
ific
chem
ical
anal
ysis
Dem
etal
lisat
ion
Cha
nge
supp
lier
Rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
GM
Pus
eof
nont
oxic
glyc
ole
Res
idue
sof
ehty
lene
glyc
ole
ampde
terg
ents
0Sp
ecifi
cch
emic
alan
alys
isD
ilutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Alc
ohol
addi
tion
(CC
P6)
CC
ertifi
edsu
pplie
rM
etha
nolc
onte
ntlt
05
gL
GC
exam
inat
ion
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erPa
steu
riza
tion
(CC
P7amp
CC
P8)
MR
unni
ngof
past
euri
ser
acco
rdin
gto
prog
ram
Det
ectio
nof
yeas
tsL
AB
en
zym
atic
activ
ity
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Tem
pera
ture
adju
stm
ent
batc
hre
proc
essi
ng
prop
erm
achi
nery
disi
nfec
tion
Qua
lity
cont
rol
man
ager
Tech
nica
lm
anag
er
aR
egar
ding
the
proc
edur
esof
bottl
ing
stor
age
and
dist
ribu
tion
the
CC
Psar
esi
mila
rto
thos
em
entio
ned
inTa
ble
1fo
rbe
erpr
oduc
tion
bM
CP
stan
dfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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2011
ORDER REPRINTS
24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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2011
ORDER REPRINTS
26 KOURTIS AND ARVANITOYANNIS
Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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2011
ORDER REPRINTS
28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
Dow
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
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ded
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irel
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] at
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ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
Dow
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irel
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itesi
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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4 KOURTIS AND ARVANITOYANNIS
in Europe Beer drinking in northern Europe dates back to early antiquity contraryto the Mediterranean countries in which wine was the commonest drink A criticalpoint in its history was the works of Louis Pasteur which greatly contributed to theunderstanding of beer production (12)
Beer Main Production Stages
The main stages for beer production are shown schematically in Figure 2together with their critical control point (CCP) numbers
Incoming Raw Materials (CCP1)
The principal raw materials used to brew beer are water malted barley hopsand yeast Barley is required to be of sufficiently good malting quality in order togerminate and to produce a satisfactory product yield Other factors such as dor-mancy and losses during malting have also to be considered (13) The malting orsubsequent brewing characteristics are subtly affected by the weather conditionsprevailing over the growing period Some information regarding the quality of abatch of barley can be obtained by visual inspection but usually it is complementedby analyses including moisture content total nitrogen 1000-grain weight and theportion of nongerminating grain The National Institute of Agricultural Botany(UK) provides descriptions of the European malting varieties Residues of certainpesticides used on malting barley survive through to the final malt and wort and canaffect the process and quality of the end product (CCP) Fungicides and herbicidesinfluencing enzyme synthesis during malting process can accumulate in the yeastthereby affecting the next fermentation (14) The critical limits of these substancesare prescribed by Codex Alimentarius and are presented in Table 1 Presence ofheavy metals above the specifications of Directive 80776EC and mycotoxin pro-duction more than 004 mgL mainly from Fusarium species such as aflatoxinsochratoxine A zearoleon deoxyniralenol constitutes a high risk for human health(CCP) (15) Temperature and relative humidity are two interacting parameters thatdefine the germination of spores of different microorganisms (16) Visual inspec-tion and biological plate methods detect the fungal contamination for mycotoxinanalysis employment of HPLC or ELISA is required (17)
The quality of the water used is a major factor affecting the beer quality(CCP) The development of strict water control standards was introduced by mostbreweries in which water is filtered through activated carbon as well as ion ex-change resins to remove impurities (pesticides herbicides and industrial wastes)Two ions of particular importance in water are calcium and carbonatebicarbonatewhich control the pH during brewing Calcium also protects α-amylase from heatdestruction thereby permitting liquefaction of starch during mashing (18)
Hops not only provide bitter flavor to the beer but impart a hoppy characteras well These aroma components are derived from the essential oil The brewing
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 5
Figure 2 Process flow diagram of beer production (2226)
value of hops depends on the resin fraction which amounts to 15 and the essentialoil comprising sim05 Total resin is defined as the material soluble in both coldmethanol and diethyl ether ldquosoftrdquo resin is that proportion of the total which issoluble in hexane comprising mainly α and β-acids while ldquohardrdquo resin is insolublein hexane The α-acids that are the most significant bittering precursors can bedistinguished from other soft resins from their ability to form a lead salt which isinsoluble in methanol The determination of moisture and seed content also provideuseful conclusions about their quality (13) Adjuncts of carbohydrate origin other
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ORDER REPRINTS
6 KOURTIS AND ARVANITOYANNIS
Tabl
e1
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rB
eer
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Mon
itori
ngC
orre
ctiv
eR
espo
nsib
lePr
oces
sSt
ep(P
MC
)aM
easu
res
CC
PPa
ram
eter
Cri
tical
Lim
itPr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
fung
ide
velo
pmen
tte
mpe
ratu
rean
dR
Hre
gula
tion
duri
ngst
orag
e
Myc
otox
inpr
oduc
tion
000
4m
gL
Vis
uali
nspe
ctio
nof
fung
ide
velo
pmen
tH
PLC
EL
ISA
E
PSan
alys
is
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
er
Cer
tified
supp
liers
sc
hedu
lein
spec
tions
Pres
ence
ofE
nter
o-ba
cter
iace
ae
0M
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Cha
nge
supp
lier
Stri
cktly
follo
win
gin
stru
ctio
nsC
onta
min
atio
nof
mic
robi
alpr
epar
atio
ns
100
clea
nC
hang
epr
epar
atio
nm
etho
dC
Effi
cien
tdis
ease
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
barl
eyh
ops
wat
er
By
pest
icid
eas
desc
ribe
dby
Cod
ex
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erC
ertifi
edsu
pplie
rsPr
oper
wat
erde
cont
amin
atio
nH
eavy
met
als
pres
ence
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Rej
ectio
nof
spec
ific
batc
hD
e-m
etal
lisat
ion
step
Use
ofde
ioni
ser
Wat
errsquos
elec
tric
alco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nise
r
Aut
omat
icdi
scon
tinua
tion
ofde
ioni
ser
anal
ysis
ofw
ater
sam
ples
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 7
Mal
ting
(CC
P2)
CU
seof
indi
rect
heat
ing
syst
ems
cont
roll
ow-N
Ox
burn
ers
ND
MA
prod
uctio
ndu
ring
kiln
ing
25
ppb
Con
tinuo
usch
ecki
ngth
ear
eas
peci
fican
alys
es
Rej
ectio
nor
mix
ing
with
othe
rba
tche
s
Qua
lity
cont
rol
man
ager
PC
ontr
olof
time
tem
pera
ture
and
RH
Col
our
and
flavo
urde
velo
pmen
tSp
ecifi
edby
part
icul
arpl
ant
Con
tinuo
usm
onito
ring
ofpr
oces
sing
cond
ition
s
Mix
ing
with
othe
rm
alts
rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
MPr
oper
hadl
ing
oper
atio
nsaf
ter
prod
uctio
n
Myc
otox
inpr
oduc
tion
000
4m
gL
Vis
uali
nspe
ctio
nof
fung
ide
velo
pmen
tH
PLC
EL
ISA
E
PSan
alys
is
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
er
Mas
hing
(CC
P3)
CC
ontr
olof
tem
pera
ture
CIP
ND
MA
prod
uctio
nde
terg
ent
resi
dues
25
ppb
Non
eC
ontin
uous
reco
rdin
gof
the
proc
essi
ng
Adj
ustl
aute
ring
prog
ram
Qua
lity
cont
rol
man
ager
Lau
teri
ng(C
CP4
)C
Sche
dule
Insp
ectio
nun
der
plat
ecl
eani
ng
AT
NC
lt20
ppb
Mic
robi
olog
ical
and
chem
ical
anal
yses
Prop
erm
aint
ain
re-l
aute
ring
ofth
eba
tch
Qua
lity
cont
rol
man
ager
Boi
ling
(CC
P5)
CC
orre
ctus
eof
boile
rtr
eatm
ent
chem
ical
s
Con
tam
inat
ion
with
dete
rgen
ts0
CIP
syst
emR
epai
rC
IPb
atch
reje
ctio
nQ
ualit
yco
ntro
lm
anag
erFe
rmen
tatio
n(C
CP6
)M
Aer
atio
nof
wor
tus
eof
yeas
tfor
max
6ge
nera
tions
Poor
yeas
tvi
abili
tyldquo
stuc
krdquofe
rmen
tatio
n
Min
90
viab
leye
astc
ell
Yea
stco
ncen
trat
ion
ferm
enta
bilit
yO
2co
ncen
trat
ion
inth
ew
ort
Incr
ease
prop
agat
ion
freq
uenc
yw
ort
aera
tion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
8 KOURTIS AND ARVANITOYANNIS
Tabl
e1
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Mon
itori
ngC
orre
ctiv
eR
espo
nsib
lePr
oces
sSt
ep(P
MC
)aM
easu
res
CC
PPa
ram
eter
Cri
tical
Lim
itPr
oced
ures
Act
ions
Pers
onne
l
Ferm
enta
tion
(CC
P6)
MIn
spec
tion
ofC
IPsy
stem
and
equi
pmen
t
Lac
toba
cill
iac
etic
acid
bact
eria
and
wil
dye
asts
Pres
ence
in1
mL
plat
e+1
mL
actid
ione
Plat
eco
unt
met
hod
ora
rapi
dde
tect
ion
met
hod
Prop
erdi
sinf
ectio
nof
equi
pmen
tre
proc
essi
ngof
the
batc
h
Qua
lity
cont
rol
man
ager
Filtr
atio
n(C
CP7
)C
Use
CO
2
prefi
lling
offil
ter
with
wat
er
O2
upta
kegt
02
ppm
diss
olve
dO
2
Mea
sure
men
tof
diss
olve
dO
2
Surv
eyof
filtr
atio
nfo
rin
crea
sed
O2
pick
up
Qua
lity
cont
rol
man
ager
Bot
tlec
anin
spec
tor
(CC
P8)
CG
MP
Cle
anin
gpe
rfor
man
ceN
oso
lids
noliq
uid
rem
nant
sE
labo
rate
elec
tron
icre
cogn
ition
syst
ems
afte
rC
IP
Rew
ashi
ngof
bottl
esC
IPsy
stem
insp
ectio
n
Qua
lity
cont
rol
man
ager
PC
ertifi
edsu
pplie
rpr
oper
hand
ling
ofbo
ttles
Bot
tles
prop
erfo
rfo
ods
and
drin
ks
bottl
esco
nditi
on
Cra
cks
scra
tche
sab
senc
eO
n-lin
evi
sual
cont
rol
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlec
anfil
ler
(CC
P9)
CIn
stal
latio
nof
cont
rolli
ngeq
uipm
ento
nth
eC
IPsy
stem
Con
tam
inat
ion
with
dete
rgen
tsC
ompl
ete
abse
nce
Org
anol
eptic
exam
inat
ion
offil
led
bottl
es
Bat
chre
ject
ion
Tra
ined
pers
onne
l
Bot
tlec
anse
aler
(CC
P10)
PC
orre
ctin
stal
latio
nof
equi
pmen
tB
low
-off
effe
ctO
ccur
renc
ere
duce
dto
anac
cept
able
leve
l
Con
trol
sets
ealin
gpr
essu
reA
utom
atic
rem
oval
ofde
stro
yed
bottl
es
Tra
ined
pers
onne
l
Bot
tlec
anpa
steu
riza
tion
(CC
P11)
PR
unni
ngpa
steu
rise
rac
cord
ing
topr
ogra
m
Oxi
datio
nca
used
ofw
rong
tem
pera
ture
-tim
ese
t
Max
65 C
for
20m
inq
uick
cool
ing
atth
eex
it
Con
tinuo
uson
-lin
etim
e-te
mpe
ratu
rech
ecki
ng
Adj
ust
tem
pera
ture
m
aint
ain
equi
pmen
t
Tech
nica
lm
anag
er
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 9
Bot
tlec
anin
spec
tion
(CC
P12)
PR
egul
arin
spec
tion
ofth
em
achi
nery
Phys
ical
dam
age
Occ
urre
nce
redu
ced
toan
acce
ptab
lele
vel
On-
line
mon
itori
ngE
quip
men
tst
anda
rdis
atio
nTe
chni
cal
man
ager
Lab
elin
g(C
CP1
3)P
Car
eful
sele
ctio
nof
the
etiq
uette
sM
ispl
aced
etiq
uette
sR
educ
edto
anac
cept
able
leve
lV
isua
lche
cks
cont
rolo
fth
eeq
uipm
ent
Rel
abel
ing
the
spec
ific
batc
hT
rain
edpe
rson
nel
Bot
tlec
anpa
ckag
ing
(CC
P14)
PC
orre
ctin
stal
latio
nof
the
equi
pmen
tB
ottle
sco
nditi
ondu
ring
palle
tisat
ion
Abs
ence
ofri
fts
inth
elu
tec
rack
orsc
ratc
hes
On-
line
visu
alco
ntro
lA
djus
tthe
equi
pmen
tpa
ram
eter
s(s
peed
pre
ssur
e)
Tech
nica
lm
anag
er
Stor
age
(CC
P15)
PC
ontr
olst
orag
eco
nditi
ons
Org
anol
eptic
cond
ition
ofbe
erSp
ecifi
edby
the
part
icul
arpl
ant
Sche
dule
dco
ntro
lsof
finis
hed
prod
uct
Adj
ustt
hest
oreh
ouse
cond
ition
s
Tra
ined
pers
onne
l
aP
MC
stan
dfo
rph
ysic
alm
icro
biol
ogic
alan
dch
emic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
10 KOURTIS AND ARVANITOYANNIS
than malt are sometimes used as an additional source of extract to supplementmalt Unmalted cereal adjuncts usually contain no active enzymes and thereforerely on malt or exogenous enzymes to provide the necessary enzymes for starchconversion (19)
Yeast growth cannot be separated from the fermentation process and it isnecessary to the production of both beer and fresh yeast for use in subsequentfermentations The quality control of yeasts comprises a) the selection maintenanceand supply of a suitable strain and b) the routine assessment of purity and detectionof microbial contamination (CCP) (20)
Malting (CCP2)
This process involves steeping the barley in a shallow bed of water at a tem-perature of 10ndash15C so that its moisture content amounts to 45 wt- of barleyBarley is then allowed to germinate under controlled temperature conditions atapproximately 15C and RH100 with constant turning to prevent matting therootlets The barleycorn undergoes germination through air passage via the germi-nating malt for 3ndash5 days Gentle heating stops germination due to moisture removaland promotes formation of flavor compounds The kiln temperature regime is cru-cial for the color of malt and the survival of enzymes to be used in the mashingprocess Kilning duration usually varies between 24 and 48 h Time temperatureand moisture content are varied to control color and flavor development Chemicalmicrobiological and physical hazards may be encountered in this step In partic-ular nitrosodimethylamine (NDMA) production during kilning (reaction of NOx
with organic materials) constitutes a chemical hazard with a critical limit (CL) at25 ppb because of its suspected carcinogenic effect In addition mycotoxin pro-duction more than 0004 mgL and color and flavor alteration represent chemicaland physical hazards respectively The NDMA content in malt can be controlled byusing indirect heating systems or by carefully maintained and controlled low-NOx
burners Regular checks should nevertheless be carried out by the maltster so thatthe residual risk caused by polluted air is kept as low as possible (17) The finishedmalt has its rootlets removed and is screened to produce the uniform quality Duringthe malting process two important changes occur a) the barley develops its ownenzyme systems and b) the naturally produced enzymes start to break down the cellstructure of the endosperm (19) Malt quality control tests include hot water extractcolor soluble nitrogen total nitrogen moisture enzyme activities viscosity andlautering prediction tests The microbiological status of malt used in the followingsteps (CCP) is very much dependent on its handling operations after production (16)
Milling
The main function of dry or wet milling is to reduce the malt particle sizeto form grist (ground or milled grain) The particle size reduction facilitates the
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 11
extraction of soluble components mainly sugars and nitrogenous compounds fromthe endosperm (21)
Mashing (CCP3)
Mashing the first step in wort production involves extracting soluble materi-als from the milled malt This is accomplished by feeding the grist through Steelrsquosmasher a hydrator consisting of a large-bore tube bent at right angles During itspassage through the vertical portion of tube the grist is spayed with hot water (typ-ically 65C) and then mixed with the help of a revolving screw (22) The floatingendosperm particles hydrate and undergo further amylolytic scission by α- andβ-amylases Processors adjust the pH and temperature conditions to allow bothenzymes with a range of susceptibility to pH and temperature to work effectivelyNDMA production (CL = 25 ppb) as well as possible detergent residues constitutepotential chemical hazards for public health Continuous monitoring at the process-ing and adjustment of the lautering program and Cleaning In Place (CIP) systemwhen deviation occurs are proper preventive and corrective actions respectively
Lautering (CCP4)
The lauter tun is a vessel normally rinsed thoroughly with a sparging or hotwater delivery system before receiving the mash which precipitates at the flat floorof slotted stainless steel or brass plates At tun center there is a lautering machineon the shaft of which rotating rakes are attached to facilitate draining the wortinto a collection vessel called grant The wort is recirculated through the lauter tununtil it reaches a certain degree of clarity whereupon it is delivered to the kettle(21) In lautering production of Apparent Total N-nitroso compounds (ATNC)above the CL of 20 ppb constitute a CCP that should be monitored with chemicaland microbiological analyses Scheduled inspection and under-plate cleaning canprevent insufficient separation of trub from wort (23)
Boiling (CCP5)
Wort is boiled for up to 2 h at atmospheric pressure following the additionof hops (CCP) The shape of copper boiling time and temperature can affect thequality of produced beer The major objectives of wort boiling are a) wort steril-ization and enzyme inactivation b) extraction of bitter and other substances fromhops and formation of flavor compounds and c) evaporation of excess water andwort concentration evaporation of undesirable flavour volatiles Wort contamina-tion of the wort with Enterobacteriaceae from hops can result in various off-flavorsincluding ldquovegetablerdquo and ldquophenolicrdquo taints (24) Correct use of boiler treatmentchemicals steam condensate tasting for carrying over the taints and operation of
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ORDER REPRINTS
12 KOURTIS AND ARVANITOYANNIS
phenol analyses are all essential to avoid chemical contamination and taints devel-opment (23)
Clarification
Wort clarification is conducted either through sedimentation or filtrationWhen whole hop cones are used it is necessary to employ either a hop back ora hop separatorndashfilter The drop in hop usage and the widespread acceptance ofpreisomerized extracts led to utilization of a vertical cylinder known as whirlpoolwhich induces sustainable circulation of the trub collecting as a compact cone in thebase Whirlpools are more suited to larger worts and can also be used with ale Inmodern breweries centrifuges constitute a promising alternative to whirlpools (25)
Cooling
To prepare for fermentation the clear hopped wort is cooled usually in aplate heat exchanger During cooling it is advisable to aerate or even to oxygenatethe wort because next processing step involves yeast growth promoted in the pres-ence of dissolved oxygen despite the low dissolved oxygen concentration in wort(7ndash14 ppm) (22)
Fermentation (CCP6)
Fermentation aims at producing ethanol by fermenting yeasts Yeasts vary intheir behavior during fermentation some strains tend to flocculate trap plug CO2 andrising to the top whereas others do not flocculate and precipitate Several lagers areproduced by bottom fermentation while many types of ales and stouts are producedby top fermentation Saccharomyces cerevisiae is usually the top fermenting yeastin the range of 18ndash22C whilst the bottom-fermenting are strains of Saccharomycesuvarum that function in the range of 7ndash15C (26) Therefore the temperature atwhich fermentation occurs is very crucial for the further stages of beer productionThe modern use of cylindroconical vessels has reduced the fermentation periodfor ales and lagers from 7 to 2 or 3 days and from 10 to 7 days respectively (27)Fermentation is monitored by taking samples for measuring the specific gravityand can be controlled by varying the cooling rate (20) ldquoStuckrdquo fermentation wherethe required ethanol level is not attained and microbial contamination with Lacticacid bacteria mainly Lactobacilii and Pediococcus which cause taints duringmaturation or in bottle storage (28) represent microbiological hazards which arethe only hazard detected at this stage Common causes for ldquostuckrdquo fermentationinclude premature yeast flocculation and yeast failure to metabolize maltotriosedue to repression by glucose (25) A minimum of 90 viable yeast cells (CL) canbe applied to ensure the development of the process During fermentation the pH
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 13
drops from 52 to 42 and by its completion the yeast is removed either as a top orbottom crop and retained to pitch the next fermentation Apart from the conventionalmicrobial detection methods with plate count several rapid detection methodspotentially applied in breweries such as ATP bioluminescence flow cytometryand polymerase chain reaction have been developed to reduce the incubation timefrom 3ndash4 days to 1ndash2 (2930)
Maturation
Maturation includes all those changes occurring between the end of primaryfermentation to beer filtration (31) Ale is matured at relatively warm temperatures12ndash20C while lagers are held under much cooler conditions The warmer temper-atures allow the rapid metabolism of any residual and priming sugars as well asloss of green flavors within 1ndash2 weeks depending on beer type yeast strain wortcomposition and primary fermentation conditions In case of lager the beer used tobe held at refrigerated temperatures for up to several months after fermentation al-lowing formation of proteintannin complexes (18) Today the enzyme addition hassubstantially shortened this process to several weeks during which flavor maturesEnzymes such as papain may be added during transfer between fermentation andmaturation tank The dosage of the proteolytic enzyme varies depending on typeof beer and process Enzyme activity decreases progressively during maturationuntil its inactivation with pasteurization Part of the enzyme absorbed in the yeastsurface is removed during filtration (19)
Filtration (CCP7)
Beer produced during fermentation is turbid and should be clarified prior to itsmarketing This turbidity is due to the presence of yeasts and proteinaceous materi-als associated with carbohydrates and polyphenols The formation of these proteinprecipitates is attributed to cold temperature low pH and poor solubility in alcoholicsolutions (32) To prevent this from occurring in the final product the beer may besubjected to various chill-proofing treatments during its storage These treatmentsgenerally include the addition of clays to absorb the colloidal materials or prote-olytic enzymes used to further solubilize the protein fraction (33) Since oxygenuptake during this process could severely affect the product organoleptic charac-teristics a CCP of dissolved oxygen should be applied with a CL of 02 ppm (34)
Packaging and Sealing
The packing section comprises several CCPs including the containers to beused their cleaning and disinfection (CCP8) the filler line (CCP9) and the sealer(CCP10) The bursting pressure of the bottles as guaranteed by the manufacturerin his specifications for the new glass may no longer be valid in case of reusable
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ORDER REPRINTS
14 KOURTIS AND ARVANITOYANNIS
bottles due to the considerable physical stress during already exerted upon themduring the filling process Insufficient cleaning of reusable bottles due to low temper-atures and concentrations of the employed cleaning solutions as well as presence ofextraneous entrapped materials within bottles and improper emptying consist pos-sible hazards Moreover cleaning solution remnants and shards introduced throughthe procedure pose problems under working conditions The beer filler may be con-taminated by cleaning and disinfection solutions Contamination sources may bedue to inadequate pressure or faulty CIP system resulting in cleaning and disinfect-ing solution remains in the pressure tank or the ring bowl of the filler (3536) Thecrown corker should be correctly installed the filling pressure of bottle caps on themouths of the bottles should be adjusted to ensure a specified blow-off effect toavoid bottle bursting After filling there should be a full bottle inspector detectingglass particles in bottles or possible leakage (37)
Bottle Pasteurization (CCP11)
Pasteurization is carried out to ensure the beer shelf life over a period ofmonths This is accomplished by the development of tunnel pasteurization in whichthe beer bottle is subjected to 60C for 20 min Over-pasteurization which causesoxidation and can adversely affect beer flavor (38) is a potential physical hazardFurthermore it is crucial to check the time-temperature procedure with adequatecorrective actions for assuring the production of a satisfactory product
Bottle Inspection (CCP12)
Bottle inspection after the pasteurization step is important to ensure that bottleshave not been damaged during the process (39) Should such a situation occur theequipment has to be standardized by the production engineer
Labeling and Standardization (CCP13)
Labeling of the package should comply with the requirements of the CodexGeneral for the labeling of prepackaged foods (40) This means that the name of theproduct shall be clearly declared there must be a list of ingredients in descendingorder of proportion no other fruit may be represented pictorially except those usedand ldquothe date of minimum durabilityrdquo will be declared by the month and year inuncoded numerical sequence
BottleCan Packaging (CCP14)
Bottles (cans) are packaged into paperboard boxes of various sizes accordingto the bottle or can dimensions The encountered hazards can be of physical natureconcerning the bottles (cans) condition during the procedure
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 15
Storage (CCP15)
The finished beer undergoes chemical microbiological and organoleptic anal-ysis to ensure that its properties are within its specification range A synoptical pre-sentation of the occurring hazards CCPs CLs and preventive corrective measuresis given in Table 1
SAKE
Introduction
Sake is a fermented liquor made from rice and coming in many varietiesdepending on the raw materials manufacturing process and process after brewing(41) According to the earliest records sake was originally brewed from rice thathad been chewed to reach saccharification followed by natural fermentation Sakebrewed this way was used as a sacred wine in the worship of the Shinto gods Thisassociation with religion Shintoism and Buddhism has caused a deep intertwiningof sake with the traditions and social customs of Japan Thus today sake is servedat ceremonies and celebrations of all kinds (42) Sake has the highest alcoholpercentage by volume of any fermented beverage In its natural undiluted state itmay contain a potent 20 ethanol compared to 3ndash5 for beer or 9ndash12 for winewhich may reach higher values for fortified wines (4344) The central brewersrsquounion divides sake into four basic flavor types on four axes of sweet sour bitterand umai The latter is another translatorrsquos nightmare which generally ends uptranslated as delicious According to position established along these axes sakeis considered to be of ldquomature typerdquo ldquofragrant typerdquo ldquolight and smooth typerdquo orldquofull-bodied typerdquo (Fig 3) However no set of criteria can adequately express themultiplicity of sensations that together create the flavor unique to any individualsake but there is a perceived need for terms which quickly and simply give thegeneral idea
Figure 3 Main flavor types for sake characterization (43)
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ORDER REPRINTS
16 KOURTIS AND ARVANITOYANNIS
Sake Main Production Stages
The main stages for sake production are schematically presented in Figure 4
Raw Materials (CCP1)
The main ingredients of Japanese sake are rice sake rice sake yeastand water The rice most suitable for sake should consist of large grains and shouldbe soft with a white part at its center due to coarse cell structure Rice should complywith the maximum residue limits for pesticides and insecticides established by theCodex Alimentarius Commission for this commodity (45) (CCP chemical hazard)For Japanese sake yellow koji mold (Aspergillus oryzae) is used Sake yeast (Sac-charomyces cerevisiae) is a microbe converting the occurring glucose and mineralsin rice and water into alcohol Employment of bubble-free type yeast eliminates
Figure 4 Process flow diagram of sake production (264647)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 17
the bubble removal step thus shortening the brewing period and reducing the costShould the factory wish to employ a specific yeast an adequate disinfection ofthe building interior is required otherwise undesirable bacteria may be introducedwhich could prove hazardous to human health (CCP microbiological hazard) (46)
Rice Polishing (CCP2)
The brown rice used for sake production must be first polished to remove theouter portion of the grain which contains fats proteins minerals and amino acidsthat can cause unpleasant flavors leaving the starch residues that are located in thecenter of the grain Nowadays machines are programmed to automatically removewhatever portion of the rice is required for the specific sake (47) The rice polishingratio (73ndash35) is expressed by the following formula (43)
Rice polishing ratio=(weight of white riceweight of brown rice)times100 (1)
The polishing process should be gently carried out because friction results inheat generation thereby greatly affecting water absorption and rice grain structureBroken grains are unlikely to satisfactorily ferment (47) Maybe the most importantstage in sake production consists of yeast starter mash production which can takeplace either with the classical Kimoto or slightly revised Yamahai process or withthe new ldquohigh speedrdquo methods (48)
Washing (CCP3)
After the rice has been polished rice powder clinging to the grain surface isremoved by washing Washing can be carried out either mechanically or manually(laborious hand washing) and should result in removing most of the organic andinorganic impurities reaching the CLs set by Codex Alimentarius of 15 and01 mm respectively
Soaking (Steeping)
Soaking allows rice to absorb the desired amount of water that is crucial toestablishing the rice consistency For sake produced ldquoen masserdquo simply dumpinginto a vat overnight for as long as 14 h is a usual case (47) However high polishedrice may be soaked within minutes In such a case an error of a minute might proveto have dire consequences for the end product (43)
Steaming (CCP4)
Steaming aims at softening the rice grains and breaking down the starchmolecules thus encouraging the growth of Aspergillus oryzae and eliminating all
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ORDER REPRINTS
18 KOURTIS AND ARVANITOYANNIS
other microorganisms leaving an initially sterile environment prone to sake moldpropagation Presence of lactic acid bacteria (LAB) and yeasts may occur at theend of this step representing a microbiological hazard and resulting in consider-able organoleptic losses The time can vary from 20 to 60 min depending on thebrewer and apparatus employed (40ndash60 and 20 min for traditional and automatedrespectively) (4346)
Cooling
The ensuing division of steamed rice is mainly related to its further use Apart of it is directly cooled by air blower whereas 20ndash30 is transferred to a heatedculture room to be infected with bacteria spores (Aspergillus oryzae) for sake moldproduction
Koji
Since rice grains contain no sugar it is the action of koji mold that converts thestarch in the grains to sugar The steamed rice is first cooled to 15ndash36C before beingtransferred to the koji culture room (30C) Spores of the mold are sprinkled likefine dust on the rice when it has cooled down to 33C After the spores are kneadedinto the steamed rice the rice is heaped and wrapped in cloths to prevent heat andmoisture loss which are two crucial factors for satisfactory bacterial growth Tomaintain uniform temperature and moisture rice is spread and mixed twice the firsttime after 20 hours (upon the appearance of white flecks) and then 7ndash8 h thereafteraccompanied by a distinctive aroma release (48)
Main Mash (Moromi) and Fermentation (CCP5)
In fermentation the occurring chemical hazards are related to heavy metalspresence (As lt 02 Cd lt 001 Pb lt 03 mgL) pesticide residues (as mentionedin Codex Alimentarius) and residues of detergents (absence) and ethylene glycole(absence) Their CLs can be determined and monitored with specific chemicalanalyses The ingredients of main mash (water koji rice and steamed rice) areadded to the starter mash in three steps (moving from small to bigger recipient)over a period of 4 days at successively lower temperatures thus preventing thegrowth of airborne bacteria (Table 2) A day after the addition of all the ingredientsformation of a moist surface showing clear cracks occurs Furthermore the mashbegins to bubble (indication of fermentation progress) as gas is given off during theburgeoning fermentation The fermentation can take place at various temperaturesand its duration depends on it that is at lower temperatures it takes up to twoweeks but the sake aroma is much more appealing compared to that formed athigher temperatures The characteristic sake aroma results from combined flavor
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 19
Table 2 Quantities of Ingredients at Each Stage of Mixing the Main Mash (Moromi)
Yeast 1st 2nd 3rd 4thStarter (Moto) Addition Addition Addition Additiona Total
Total rice (kg) 210 470 850 1470 3000Steamed rice (kg) 140 330 650 1230 2350Koji rice (kg) 70 140 200 240 65030 Brewerrsquos 1200 1200
alcohol (L)Water (L) 230 420 1010 2030 360 405
aTraditional brewers mix the final mash in three stages The fourth addition of alcohol and wateris a controversial postwar development (Kondo 1984)
components of a number of compounds produced during fermentation (49) Theelevated alcohol content of the fermented sake is related to lipid metabolism ofyeast in the presence of proteolipid provided by the koji molds (5051)
Additions (CCP6)
The addition of alcohol at this stage is carried out unless it is clearly statedthat sake does not contain any alcohol from extraneous sources The added alcoholshould not contain methanol or if it does the content of the latter should be lessthan 05 gL because of its toxicity (CCP chemical hazard)
Pressing
Automatic machine presses (consisting of a series of panels with balloon-likesacks attached) are most widely used nowadays instead of the traditional time-consuming method using long bags The remained caked lees are employed forpickle production and cooking or sedimentation of rice particles may occur Alter-natively sedimentation of rice particles at the bottom of the tank may take place
Filtration
Coloring and aging (maturation) inhibition can be effected by using activatedcharcoal filters
Pasteurization (CCP7 and CCP8)
Heating sake preferably twice at 65C kills off the remaining yeast stops en-zyme action and deactivates the lactic acid bacteria that will eventually spoil sakeThis process represents a microbiological hazard for which the specific plant may
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ORDER REPRINTS
20 KOURTIS AND ARVANITOYANNIS
set CLs However in recent years refrigerated storage and transport have madeunpasteurized sake with characteristic aroma available to the consumer (43)
Dilution
The produced sake in its raw state (Genchu) contains more than 20 alcoholby volume but it is generally diluted to about 15ndash16 vol-
BottlingStorageDistribution
The applied procedures are similar to those mentioned for the beer productionA summary of the occurring hazards CCPs CLs and preventive and correc-
tive measures is given in Table 3
WINE
Introduction
Wines are made from the fruit of Vitis vinifera of which there are a greatnumber of varieties growing in many parts of the world The history of wine isinextricably interwoven with human history It might be as true to say that it waswith wine that civilization began for the vine takes longer to mature than any othercrop and does not produce grapes for wine making until its fourth year It is notexactly known when men first had wine but it was accepted as a gift from the godsthe Egyptians attributed it to Osiris and the Greeks to Dionysos Mesopotamia andthe Caucasian slopes were no doubt early sources of wine from where it was spreadto Egypt and Greece and then to the rest of the world (52)
Wine Main Production Stages
The main stages for wine production are schematically presented in Figure 5
Harvesting (CCP1)
Grape harvesting is a CCP comprising both physical and chemical hazardsPhysically the grapes should be sound without rotten parts otherwise oxidativeand microbial contamination can rapidly develop Therefore harvesting shouldbe conducted with the greatest possible care and an efficient disease managementsystem should be applied (5354) Pesticides play an important role in pest man-agement but they should be handled with care because they constitute chemicalhazards (55) At the time of harvest the grapes must have also reached the correctmaturity when Brix and Total Acidity (TA) levels indicate maturity of wine Sincepesticide and fungicide residues on the surface of the berries constitute chemical
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 21
hazards Oliva et al (56) proposed a rapid and simple gas chromatographic methodfor their determination The maximum residue limits for pesticides in grapes andwines are provided by Codex Alimentarius (45) and Organisation International duVin (57) Finally the bulk bins used for grapes transportation should be effectivelydecontaminated to avoid any microbial infection
Stemming
Stemming includes the removal of stem leaves and grape stalks before crush-ing This procedure has several advantages because the total volume of processedproduct drops by 30 thus resulting in smaller tanks and eventually increasingthe productrsquos alcoholic content (58) However the end of fermentation and the al-cohol content of finished product depend mostly on the Brix level of initial grapesStemmers usually contain a perforated cylinder allowing berries to pass throughbut prevent the passage of stems stalks and leaves
Crushing
Crushing typically immediately follows stemming since some crushing ofthe fruit occurs during stemming The released juice is highly susceptible to oxida-tive browning and microbial contamination The most common crushing processesinvolve pressing the fruit against a perforated wall or passing the fruit through a setof rollers It is very important to avoid crushing the seeds to preclude contaminat-ing the must with seed oils the oxidation of which could produce rancid odors andconstitute an undesirable source of bitter tannins Equally important is the properhandling of product because inappropriate timing might lead to a sudden startof alcoholic fermentation and consequently to higher fermentation temperatureswhile a delay might cause microbial contamination and oxidative browning (59)
Maceration
Maceration is the breakdown of grape solids after crushing of grapes Whilemaceration is always involved in the initial stage of red wine fermentation the long-standing trend has been to limit maceration in white wine production Temperatureand duration of maceration depend on grape and wine variety Usually for white androse wines the maceration time is less than 24 h red destined for early consumptionis macerated for 3ndash5 days and red for aging is macerated from 5 days to 3 weeksFermentation usually occurs during this or at the end of maceration The amount ofthe antimicrobial to be used usually added to white musts that are most sensitive tooxidation depends on the crop health and maceration temperature Sulfur dioxidehas a distinct advantage over other antimicrobial agents because of the relativeinsensitivity of the wine yeasts to its action However it is also toxic or inhibitoryto most bacteria and yeasts (ie Candida Pichia Hansenula) at low concentrations(60) and has a rather low retention capability after the clarification step (61)
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ORDER REPRINTS
22 KOURTIS AND ARVANITOYANNISTa
ble
3Su
mm
ary
ofH
azar
dsC
CPs
CL
sM
onito
ring
Cor
rect
ive
Act
ions
and
Pers
onne
lRes
pons
ible
for
Sake
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
a(M
CP
)bM
easu
res
CC
PPa
ram
eter
(CL
s)Pr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
CC
ertifi
edsu
pplie
rs
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
wat
er
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Cer
tified
supp
liers
Hea
vym
etal
spr
esen
cein
wat
er
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Eva
luat
ion
ofth
ede
cont
amin
atin
gm
etho
ds
MC
ertifi
edsu
pplie
rs
prop
erpr
epar
atio
n
Mic
robi
alco
ntam
inat
ion
ofth
ecu
lture
100
clea
nM
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Wat
erm
icro
biol
ogic
alqu
ality
Abs
ence
ofpa
thog
ens
Insp
ectio
nof
the
equi
pmen
t
Ric
epo
lishi
ng(C
CP2
)C
Cer
tified
supp
lier
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
polis
hed
rice
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Was
hing
(CC
P3)
PC
ertifi
edsu
pplie
rs
inst
alla
tion
ofau
tom
atic
sepa
rato
r
Ani
mal
impu
ritie
sO
ther
orga
nic
and
inor
gani
cm
ater
01
mm
15
mm
01
mm
Spec
ific
exam
inat
ion
Rew
ashi
ngof
spec
ific
batc
hch
ange
supp
lier
Qua
lity
cont
rol
man
ager
Stea
min
g(f
orun
past
euri
sed
sake
)(C
CP4
)
MG
MP
sche
dule
dm
icro
biol
ogic
alco
ntro
ls
Pres
ence
ofye
asts
and
LA
B
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Spec
ific
batc
hre
proc
essi
ng
CIP
stan
dar-
disa
tion
Qua
lity
cont
rol
man
ager
T
rain
ned
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 23
Ferm
enta
tion
(CC
P5)
CM
ater
ialc
ontr
ol
GM
Pco
rros
ion
chec
ks
Hea
vym
etal
pres
ence
Pest
icid
ere
sidu
es
Aslt
02
Cd
lt
001
Pb
lt
03
(mg
L)
Spec
ific
chem
ical
anal
ysis
Dem
etal
lisat
ion
Cha
nge
supp
lier
Rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
GM
Pus
eof
nont
oxic
glyc
ole
Res
idue
sof
ehty
lene
glyc
ole
ampde
terg
ents
0Sp
ecifi
cch
emic
alan
alys
isD
ilutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Alc
ohol
addi
tion
(CC
P6)
CC
ertifi
edsu
pplie
rM
etha
nolc
onte
ntlt
05
gL
GC
exam
inat
ion
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erPa
steu
riza
tion
(CC
P7amp
CC
P8)
MR
unni
ngof
past
euri
ser
acco
rdin
gto
prog
ram
Det
ectio
nof
yeas
tsL
AB
en
zym
atic
activ
ity
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Tem
pera
ture
adju
stm
ent
batc
hre
proc
essi
ng
prop
erm
achi
nery
disi
nfec
tion
Qua
lity
cont
rol
man
ager
Tech
nica
lm
anag
er
aR
egar
ding
the
proc
edur
esof
bottl
ing
stor
age
and
dist
ribu
tion
the
CC
Psar
esi
mila
rto
thos
em
entio
ned
inTa
ble
1fo
rbe
erpr
oduc
tion
bM
CP
stan
dfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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ORDER REPRINTS
26 KOURTIS AND ARVANITOYANNIS
Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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2011
ORDER REPRINTS
28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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2011
ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
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yman
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irel
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
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ded
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yman
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irel
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ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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irel
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itesi
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 5
Figure 2 Process flow diagram of beer production (2226)
value of hops depends on the resin fraction which amounts to 15 and the essentialoil comprising sim05 Total resin is defined as the material soluble in both coldmethanol and diethyl ether ldquosoftrdquo resin is that proportion of the total which issoluble in hexane comprising mainly α and β-acids while ldquohardrdquo resin is insolublein hexane The α-acids that are the most significant bittering precursors can bedistinguished from other soft resins from their ability to form a lead salt which isinsoluble in methanol The determination of moisture and seed content also provideuseful conclusions about their quality (13) Adjuncts of carbohydrate origin other
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6 KOURTIS AND ARVANITOYANNIS
Tabl
e1
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rB
eer
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Mon
itori
ngC
orre
ctiv
eR
espo
nsib
lePr
oces
sSt
ep(P
MC
)aM
easu
res
CC
PPa
ram
eter
Cri
tical
Lim
itPr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
fung
ide
velo
pmen
tte
mpe
ratu
rean
dR
Hre
gula
tion
duri
ngst
orag
e
Myc
otox
inpr
oduc
tion
000
4m
gL
Vis
uali
nspe
ctio
nof
fung
ide
velo
pmen
tH
PLC
EL
ISA
E
PSan
alys
is
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
er
Cer
tified
supp
liers
sc
hedu
lein
spec
tions
Pres
ence
ofE
nter
o-ba
cter
iace
ae
0M
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Cha
nge
supp
lier
Stri
cktly
follo
win
gin
stru
ctio
nsC
onta
min
atio
nof
mic
robi
alpr
epar
atio
ns
100
clea
nC
hang
epr
epar
atio
nm
etho
dC
Effi
cien
tdis
ease
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
barl
eyh
ops
wat
er
By
pest
icid
eas
desc
ribe
dby
Cod
ex
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erC
ertifi
edsu
pplie
rsPr
oper
wat
erde
cont
amin
atio
nH
eavy
met
als
pres
ence
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Rej
ectio
nof
spec
ific
batc
hD
e-m
etal
lisat
ion
step
Use
ofde
ioni
ser
Wat
errsquos
elec
tric
alco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nise
r
Aut
omat
icdi
scon
tinua
tion
ofde
ioni
ser
anal
ysis
ofw
ater
sam
ples
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 7
Mal
ting
(CC
P2)
CU
seof
indi
rect
heat
ing
syst
ems
cont
roll
ow-N
Ox
burn
ers
ND
MA
prod
uctio
ndu
ring
kiln
ing
25
ppb
Con
tinuo
usch
ecki
ngth
ear
eas
peci
fican
alys
es
Rej
ectio
nor
mix
ing
with
othe
rba
tche
s
Qua
lity
cont
rol
man
ager
PC
ontr
olof
time
tem
pera
ture
and
RH
Col
our
and
flavo
urde
velo
pmen
tSp
ecifi
edby
part
icul
arpl
ant
Con
tinuo
usm
onito
ring
ofpr
oces
sing
cond
ition
s
Mix
ing
with
othe
rm
alts
rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
MPr
oper
hadl
ing
oper
atio
nsaf
ter
prod
uctio
n
Myc
otox
inpr
oduc
tion
000
4m
gL
Vis
uali
nspe
ctio
nof
fung
ide
velo
pmen
tH
PLC
EL
ISA
E
PSan
alys
is
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
er
Mas
hing
(CC
P3)
CC
ontr
olof
tem
pera
ture
CIP
ND
MA
prod
uctio
nde
terg
ent
resi
dues
25
ppb
Non
eC
ontin
uous
reco
rdin
gof
the
proc
essi
ng
Adj
ustl
aute
ring
prog
ram
Qua
lity
cont
rol
man
ager
Lau
teri
ng(C
CP4
)C
Sche
dule
Insp
ectio
nun
der
plat
ecl
eani
ng
AT
NC
lt20
ppb
Mic
robi
olog
ical
and
chem
ical
anal
yses
Prop
erm
aint
ain
re-l
aute
ring
ofth
eba
tch
Qua
lity
cont
rol
man
ager
Boi
ling
(CC
P5)
CC
orre
ctus
eof
boile
rtr
eatm
ent
chem
ical
s
Con
tam
inat
ion
with
dete
rgen
ts0
CIP
syst
emR
epai
rC
IPb
atch
reje
ctio
nQ
ualit
yco
ntro
lm
anag
erFe
rmen
tatio
n(C
CP6
)M
Aer
atio
nof
wor
tus
eof
yeas
tfor
max
6ge
nera
tions
Poor
yeas
tvi
abili
tyldquo
stuc
krdquofe
rmen
tatio
n
Min
90
viab
leye
astc
ell
Yea
stco
ncen
trat
ion
ferm
enta
bilit
yO
2co
ncen
trat
ion
inth
ew
ort
Incr
ease
prop
agat
ion
freq
uenc
yw
ort
aera
tion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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2011
ORDER REPRINTS
8 KOURTIS AND ARVANITOYANNIS
Tabl
e1
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Mon
itori
ngC
orre
ctiv
eR
espo
nsib
lePr
oces
sSt
ep(P
MC
)aM
easu
res
CC
PPa
ram
eter
Cri
tical
Lim
itPr
oced
ures
Act
ions
Pers
onne
l
Ferm
enta
tion
(CC
P6)
MIn
spec
tion
ofC
IPsy
stem
and
equi
pmen
t
Lac
toba
cill
iac
etic
acid
bact
eria
and
wil
dye
asts
Pres
ence
in1
mL
plat
e+1
mL
actid
ione
Plat
eco
unt
met
hod
ora
rapi
dde
tect
ion
met
hod
Prop
erdi
sinf
ectio
nof
equi
pmen
tre
proc
essi
ngof
the
batc
h
Qua
lity
cont
rol
man
ager
Filtr
atio
n(C
CP7
)C
Use
CO
2
prefi
lling
offil
ter
with
wat
er
O2
upta
kegt
02
ppm
diss
olve
dO
2
Mea
sure
men
tof
diss
olve
dO
2
Surv
eyof
filtr
atio
nfo
rin
crea
sed
O2
pick
up
Qua
lity
cont
rol
man
ager
Bot
tlec
anin
spec
tor
(CC
P8)
CG
MP
Cle
anin
gpe
rfor
man
ceN
oso
lids
noliq
uid
rem
nant
sE
labo
rate
elec
tron
icre
cogn
ition
syst
ems
afte
rC
IP
Rew
ashi
ngof
bottl
esC
IPsy
stem
insp
ectio
n
Qua
lity
cont
rol
man
ager
PC
ertifi
edsu
pplie
rpr
oper
hand
ling
ofbo
ttles
Bot
tles
prop
erfo
rfo
ods
and
drin
ks
bottl
esco
nditi
on
Cra
cks
scra
tche
sab
senc
eO
n-lin
evi
sual
cont
rol
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlec
anfil
ler
(CC
P9)
CIn
stal
latio
nof
cont
rolli
ngeq
uipm
ento
nth
eC
IPsy
stem
Con
tam
inat
ion
with
dete
rgen
tsC
ompl
ete
abse
nce
Org
anol
eptic
exam
inat
ion
offil
led
bottl
es
Bat
chre
ject
ion
Tra
ined
pers
onne
l
Bot
tlec
anse
aler
(CC
P10)
PC
orre
ctin
stal
latio
nof
equi
pmen
tB
low
-off
effe
ctO
ccur
renc
ere
duce
dto
anac
cept
able
leve
l
Con
trol
sets
ealin
gpr
essu
reA
utom
atic
rem
oval
ofde
stro
yed
bottl
es
Tra
ined
pers
onne
l
Bot
tlec
anpa
steu
riza
tion
(CC
P11)
PR
unni
ngpa
steu
rise
rac
cord
ing
topr
ogra
m
Oxi
datio
nca
used
ofw
rong
tem
pera
ture
-tim
ese
t
Max
65 C
for
20m
inq
uick
cool
ing
atth
eex
it
Con
tinuo
uson
-lin
etim
e-te
mpe
ratu
rech
ecki
ng
Adj
ust
tem
pera
ture
m
aint
ain
equi
pmen
t
Tech
nica
lm
anag
er
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 9
Bot
tlec
anin
spec
tion
(CC
P12)
PR
egul
arin
spec
tion
ofth
em
achi
nery
Phys
ical
dam
age
Occ
urre
nce
redu
ced
toan
acce
ptab
lele
vel
On-
line
mon
itori
ngE
quip
men
tst
anda
rdis
atio
nTe
chni
cal
man
ager
Lab
elin
g(C
CP1
3)P
Car
eful
sele
ctio
nof
the
etiq
uette
sM
ispl
aced
etiq
uette
sR
educ
edto
anac
cept
able
leve
lV
isua
lche
cks
cont
rolo
fth
eeq
uipm
ent
Rel
abel
ing
the
spec
ific
batc
hT
rain
edpe
rson
nel
Bot
tlec
anpa
ckag
ing
(CC
P14)
PC
orre
ctin
stal
latio
nof
the
equi
pmen
tB
ottle
sco
nditi
ondu
ring
palle
tisat
ion
Abs
ence
ofri
fts
inth
elu
tec
rack
orsc
ratc
hes
On-
line
visu
alco
ntro
lA
djus
tthe
equi
pmen
tpa
ram
eter
s(s
peed
pre
ssur
e)
Tech
nica
lm
anag
er
Stor
age
(CC
P15)
PC
ontr
olst
orag
eco
nditi
ons
Org
anol
eptic
cond
ition
ofbe
erSp
ecifi
edby
the
part
icul
arpl
ant
Sche
dule
dco
ntro
lsof
finis
hed
prod
uct
Adj
ustt
hest
oreh
ouse
cond
ition
s
Tra
ined
pers
onne
l
aP
MC
stan
dfo
rph
ysic
alm
icro
biol
ogic
alan
dch
emic
alha
zard
sre
spec
tivel
y
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2011
ORDER REPRINTS
10 KOURTIS AND ARVANITOYANNIS
than malt are sometimes used as an additional source of extract to supplementmalt Unmalted cereal adjuncts usually contain no active enzymes and thereforerely on malt or exogenous enzymes to provide the necessary enzymes for starchconversion (19)
Yeast growth cannot be separated from the fermentation process and it isnecessary to the production of both beer and fresh yeast for use in subsequentfermentations The quality control of yeasts comprises a) the selection maintenanceand supply of a suitable strain and b) the routine assessment of purity and detectionof microbial contamination (CCP) (20)
Malting (CCP2)
This process involves steeping the barley in a shallow bed of water at a tem-perature of 10ndash15C so that its moisture content amounts to 45 wt- of barleyBarley is then allowed to germinate under controlled temperature conditions atapproximately 15C and RH100 with constant turning to prevent matting therootlets The barleycorn undergoes germination through air passage via the germi-nating malt for 3ndash5 days Gentle heating stops germination due to moisture removaland promotes formation of flavor compounds The kiln temperature regime is cru-cial for the color of malt and the survival of enzymes to be used in the mashingprocess Kilning duration usually varies between 24 and 48 h Time temperatureand moisture content are varied to control color and flavor development Chemicalmicrobiological and physical hazards may be encountered in this step In partic-ular nitrosodimethylamine (NDMA) production during kilning (reaction of NOx
with organic materials) constitutes a chemical hazard with a critical limit (CL) at25 ppb because of its suspected carcinogenic effect In addition mycotoxin pro-duction more than 0004 mgL and color and flavor alteration represent chemicaland physical hazards respectively The NDMA content in malt can be controlled byusing indirect heating systems or by carefully maintained and controlled low-NOx
burners Regular checks should nevertheless be carried out by the maltster so thatthe residual risk caused by polluted air is kept as low as possible (17) The finishedmalt has its rootlets removed and is screened to produce the uniform quality Duringthe malting process two important changes occur a) the barley develops its ownenzyme systems and b) the naturally produced enzymes start to break down the cellstructure of the endosperm (19) Malt quality control tests include hot water extractcolor soluble nitrogen total nitrogen moisture enzyme activities viscosity andlautering prediction tests The microbiological status of malt used in the followingsteps (CCP) is very much dependent on its handling operations after production (16)
Milling
The main function of dry or wet milling is to reduce the malt particle sizeto form grist (ground or milled grain) The particle size reduction facilitates the
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 11
extraction of soluble components mainly sugars and nitrogenous compounds fromthe endosperm (21)
Mashing (CCP3)
Mashing the first step in wort production involves extracting soluble materi-als from the milled malt This is accomplished by feeding the grist through Steelrsquosmasher a hydrator consisting of a large-bore tube bent at right angles During itspassage through the vertical portion of tube the grist is spayed with hot water (typ-ically 65C) and then mixed with the help of a revolving screw (22) The floatingendosperm particles hydrate and undergo further amylolytic scission by α- andβ-amylases Processors adjust the pH and temperature conditions to allow bothenzymes with a range of susceptibility to pH and temperature to work effectivelyNDMA production (CL = 25 ppb) as well as possible detergent residues constitutepotential chemical hazards for public health Continuous monitoring at the process-ing and adjustment of the lautering program and Cleaning In Place (CIP) systemwhen deviation occurs are proper preventive and corrective actions respectively
Lautering (CCP4)
The lauter tun is a vessel normally rinsed thoroughly with a sparging or hotwater delivery system before receiving the mash which precipitates at the flat floorof slotted stainless steel or brass plates At tun center there is a lautering machineon the shaft of which rotating rakes are attached to facilitate draining the wortinto a collection vessel called grant The wort is recirculated through the lauter tununtil it reaches a certain degree of clarity whereupon it is delivered to the kettle(21) In lautering production of Apparent Total N-nitroso compounds (ATNC)above the CL of 20 ppb constitute a CCP that should be monitored with chemicaland microbiological analyses Scheduled inspection and under-plate cleaning canprevent insufficient separation of trub from wort (23)
Boiling (CCP5)
Wort is boiled for up to 2 h at atmospheric pressure following the additionof hops (CCP) The shape of copper boiling time and temperature can affect thequality of produced beer The major objectives of wort boiling are a) wort steril-ization and enzyme inactivation b) extraction of bitter and other substances fromhops and formation of flavor compounds and c) evaporation of excess water andwort concentration evaporation of undesirable flavour volatiles Wort contamina-tion of the wort with Enterobacteriaceae from hops can result in various off-flavorsincluding ldquovegetablerdquo and ldquophenolicrdquo taints (24) Correct use of boiler treatmentchemicals steam condensate tasting for carrying over the taints and operation of
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ORDER REPRINTS
12 KOURTIS AND ARVANITOYANNIS
phenol analyses are all essential to avoid chemical contamination and taints devel-opment (23)
Clarification
Wort clarification is conducted either through sedimentation or filtrationWhen whole hop cones are used it is necessary to employ either a hop back ora hop separatorndashfilter The drop in hop usage and the widespread acceptance ofpreisomerized extracts led to utilization of a vertical cylinder known as whirlpoolwhich induces sustainable circulation of the trub collecting as a compact cone in thebase Whirlpools are more suited to larger worts and can also be used with ale Inmodern breweries centrifuges constitute a promising alternative to whirlpools (25)
Cooling
To prepare for fermentation the clear hopped wort is cooled usually in aplate heat exchanger During cooling it is advisable to aerate or even to oxygenatethe wort because next processing step involves yeast growth promoted in the pres-ence of dissolved oxygen despite the low dissolved oxygen concentration in wort(7ndash14 ppm) (22)
Fermentation (CCP6)
Fermentation aims at producing ethanol by fermenting yeasts Yeasts vary intheir behavior during fermentation some strains tend to flocculate trap plug CO2 andrising to the top whereas others do not flocculate and precipitate Several lagers areproduced by bottom fermentation while many types of ales and stouts are producedby top fermentation Saccharomyces cerevisiae is usually the top fermenting yeastin the range of 18ndash22C whilst the bottom-fermenting are strains of Saccharomycesuvarum that function in the range of 7ndash15C (26) Therefore the temperature atwhich fermentation occurs is very crucial for the further stages of beer productionThe modern use of cylindroconical vessels has reduced the fermentation periodfor ales and lagers from 7 to 2 or 3 days and from 10 to 7 days respectively (27)Fermentation is monitored by taking samples for measuring the specific gravityand can be controlled by varying the cooling rate (20) ldquoStuckrdquo fermentation wherethe required ethanol level is not attained and microbial contamination with Lacticacid bacteria mainly Lactobacilii and Pediococcus which cause taints duringmaturation or in bottle storage (28) represent microbiological hazards which arethe only hazard detected at this stage Common causes for ldquostuckrdquo fermentationinclude premature yeast flocculation and yeast failure to metabolize maltotriosedue to repression by glucose (25) A minimum of 90 viable yeast cells (CL) canbe applied to ensure the development of the process During fermentation the pH
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 13
drops from 52 to 42 and by its completion the yeast is removed either as a top orbottom crop and retained to pitch the next fermentation Apart from the conventionalmicrobial detection methods with plate count several rapid detection methodspotentially applied in breweries such as ATP bioluminescence flow cytometryand polymerase chain reaction have been developed to reduce the incubation timefrom 3ndash4 days to 1ndash2 (2930)
Maturation
Maturation includes all those changes occurring between the end of primaryfermentation to beer filtration (31) Ale is matured at relatively warm temperatures12ndash20C while lagers are held under much cooler conditions The warmer temper-atures allow the rapid metabolism of any residual and priming sugars as well asloss of green flavors within 1ndash2 weeks depending on beer type yeast strain wortcomposition and primary fermentation conditions In case of lager the beer used tobe held at refrigerated temperatures for up to several months after fermentation al-lowing formation of proteintannin complexes (18) Today the enzyme addition hassubstantially shortened this process to several weeks during which flavor maturesEnzymes such as papain may be added during transfer between fermentation andmaturation tank The dosage of the proteolytic enzyme varies depending on typeof beer and process Enzyme activity decreases progressively during maturationuntil its inactivation with pasteurization Part of the enzyme absorbed in the yeastsurface is removed during filtration (19)
Filtration (CCP7)
Beer produced during fermentation is turbid and should be clarified prior to itsmarketing This turbidity is due to the presence of yeasts and proteinaceous materi-als associated with carbohydrates and polyphenols The formation of these proteinprecipitates is attributed to cold temperature low pH and poor solubility in alcoholicsolutions (32) To prevent this from occurring in the final product the beer may besubjected to various chill-proofing treatments during its storage These treatmentsgenerally include the addition of clays to absorb the colloidal materials or prote-olytic enzymes used to further solubilize the protein fraction (33) Since oxygenuptake during this process could severely affect the product organoleptic charac-teristics a CCP of dissolved oxygen should be applied with a CL of 02 ppm (34)
Packaging and Sealing
The packing section comprises several CCPs including the containers to beused their cleaning and disinfection (CCP8) the filler line (CCP9) and the sealer(CCP10) The bursting pressure of the bottles as guaranteed by the manufacturerin his specifications for the new glass may no longer be valid in case of reusable
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ORDER REPRINTS
14 KOURTIS AND ARVANITOYANNIS
bottles due to the considerable physical stress during already exerted upon themduring the filling process Insufficient cleaning of reusable bottles due to low temper-atures and concentrations of the employed cleaning solutions as well as presence ofextraneous entrapped materials within bottles and improper emptying consist pos-sible hazards Moreover cleaning solution remnants and shards introduced throughthe procedure pose problems under working conditions The beer filler may be con-taminated by cleaning and disinfection solutions Contamination sources may bedue to inadequate pressure or faulty CIP system resulting in cleaning and disinfect-ing solution remains in the pressure tank or the ring bowl of the filler (3536) Thecrown corker should be correctly installed the filling pressure of bottle caps on themouths of the bottles should be adjusted to ensure a specified blow-off effect toavoid bottle bursting After filling there should be a full bottle inspector detectingglass particles in bottles or possible leakage (37)
Bottle Pasteurization (CCP11)
Pasteurization is carried out to ensure the beer shelf life over a period ofmonths This is accomplished by the development of tunnel pasteurization in whichthe beer bottle is subjected to 60C for 20 min Over-pasteurization which causesoxidation and can adversely affect beer flavor (38) is a potential physical hazardFurthermore it is crucial to check the time-temperature procedure with adequatecorrective actions for assuring the production of a satisfactory product
Bottle Inspection (CCP12)
Bottle inspection after the pasteurization step is important to ensure that bottleshave not been damaged during the process (39) Should such a situation occur theequipment has to be standardized by the production engineer
Labeling and Standardization (CCP13)
Labeling of the package should comply with the requirements of the CodexGeneral for the labeling of prepackaged foods (40) This means that the name of theproduct shall be clearly declared there must be a list of ingredients in descendingorder of proportion no other fruit may be represented pictorially except those usedand ldquothe date of minimum durabilityrdquo will be declared by the month and year inuncoded numerical sequence
BottleCan Packaging (CCP14)
Bottles (cans) are packaged into paperboard boxes of various sizes accordingto the bottle or can dimensions The encountered hazards can be of physical natureconcerning the bottles (cans) condition during the procedure
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 15
Storage (CCP15)
The finished beer undergoes chemical microbiological and organoleptic anal-ysis to ensure that its properties are within its specification range A synoptical pre-sentation of the occurring hazards CCPs CLs and preventive corrective measuresis given in Table 1
SAKE
Introduction
Sake is a fermented liquor made from rice and coming in many varietiesdepending on the raw materials manufacturing process and process after brewing(41) According to the earliest records sake was originally brewed from rice thathad been chewed to reach saccharification followed by natural fermentation Sakebrewed this way was used as a sacred wine in the worship of the Shinto gods Thisassociation with religion Shintoism and Buddhism has caused a deep intertwiningof sake with the traditions and social customs of Japan Thus today sake is servedat ceremonies and celebrations of all kinds (42) Sake has the highest alcoholpercentage by volume of any fermented beverage In its natural undiluted state itmay contain a potent 20 ethanol compared to 3ndash5 for beer or 9ndash12 for winewhich may reach higher values for fortified wines (4344) The central brewersrsquounion divides sake into four basic flavor types on four axes of sweet sour bitterand umai The latter is another translatorrsquos nightmare which generally ends uptranslated as delicious According to position established along these axes sakeis considered to be of ldquomature typerdquo ldquofragrant typerdquo ldquolight and smooth typerdquo orldquofull-bodied typerdquo (Fig 3) However no set of criteria can adequately express themultiplicity of sensations that together create the flavor unique to any individualsake but there is a perceived need for terms which quickly and simply give thegeneral idea
Figure 3 Main flavor types for sake characterization (43)
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16 KOURTIS AND ARVANITOYANNIS
Sake Main Production Stages
The main stages for sake production are schematically presented in Figure 4
Raw Materials (CCP1)
The main ingredients of Japanese sake are rice sake rice sake yeastand water The rice most suitable for sake should consist of large grains and shouldbe soft with a white part at its center due to coarse cell structure Rice should complywith the maximum residue limits for pesticides and insecticides established by theCodex Alimentarius Commission for this commodity (45) (CCP chemical hazard)For Japanese sake yellow koji mold (Aspergillus oryzae) is used Sake yeast (Sac-charomyces cerevisiae) is a microbe converting the occurring glucose and mineralsin rice and water into alcohol Employment of bubble-free type yeast eliminates
Figure 4 Process flow diagram of sake production (264647)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 17
the bubble removal step thus shortening the brewing period and reducing the costShould the factory wish to employ a specific yeast an adequate disinfection ofthe building interior is required otherwise undesirable bacteria may be introducedwhich could prove hazardous to human health (CCP microbiological hazard) (46)
Rice Polishing (CCP2)
The brown rice used for sake production must be first polished to remove theouter portion of the grain which contains fats proteins minerals and amino acidsthat can cause unpleasant flavors leaving the starch residues that are located in thecenter of the grain Nowadays machines are programmed to automatically removewhatever portion of the rice is required for the specific sake (47) The rice polishingratio (73ndash35) is expressed by the following formula (43)
Rice polishing ratio=(weight of white riceweight of brown rice)times100 (1)
The polishing process should be gently carried out because friction results inheat generation thereby greatly affecting water absorption and rice grain structureBroken grains are unlikely to satisfactorily ferment (47) Maybe the most importantstage in sake production consists of yeast starter mash production which can takeplace either with the classical Kimoto or slightly revised Yamahai process or withthe new ldquohigh speedrdquo methods (48)
Washing (CCP3)
After the rice has been polished rice powder clinging to the grain surface isremoved by washing Washing can be carried out either mechanically or manually(laborious hand washing) and should result in removing most of the organic andinorganic impurities reaching the CLs set by Codex Alimentarius of 15 and01 mm respectively
Soaking (Steeping)
Soaking allows rice to absorb the desired amount of water that is crucial toestablishing the rice consistency For sake produced ldquoen masserdquo simply dumpinginto a vat overnight for as long as 14 h is a usual case (47) However high polishedrice may be soaked within minutes In such a case an error of a minute might proveto have dire consequences for the end product (43)
Steaming (CCP4)
Steaming aims at softening the rice grains and breaking down the starchmolecules thus encouraging the growth of Aspergillus oryzae and eliminating all
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ORDER REPRINTS
18 KOURTIS AND ARVANITOYANNIS
other microorganisms leaving an initially sterile environment prone to sake moldpropagation Presence of lactic acid bacteria (LAB) and yeasts may occur at theend of this step representing a microbiological hazard and resulting in consider-able organoleptic losses The time can vary from 20 to 60 min depending on thebrewer and apparatus employed (40ndash60 and 20 min for traditional and automatedrespectively) (4346)
Cooling
The ensuing division of steamed rice is mainly related to its further use Apart of it is directly cooled by air blower whereas 20ndash30 is transferred to a heatedculture room to be infected with bacteria spores (Aspergillus oryzae) for sake moldproduction
Koji
Since rice grains contain no sugar it is the action of koji mold that converts thestarch in the grains to sugar The steamed rice is first cooled to 15ndash36C before beingtransferred to the koji culture room (30C) Spores of the mold are sprinkled likefine dust on the rice when it has cooled down to 33C After the spores are kneadedinto the steamed rice the rice is heaped and wrapped in cloths to prevent heat andmoisture loss which are two crucial factors for satisfactory bacterial growth Tomaintain uniform temperature and moisture rice is spread and mixed twice the firsttime after 20 hours (upon the appearance of white flecks) and then 7ndash8 h thereafteraccompanied by a distinctive aroma release (48)
Main Mash (Moromi) and Fermentation (CCP5)
In fermentation the occurring chemical hazards are related to heavy metalspresence (As lt 02 Cd lt 001 Pb lt 03 mgL) pesticide residues (as mentionedin Codex Alimentarius) and residues of detergents (absence) and ethylene glycole(absence) Their CLs can be determined and monitored with specific chemicalanalyses The ingredients of main mash (water koji rice and steamed rice) areadded to the starter mash in three steps (moving from small to bigger recipient)over a period of 4 days at successively lower temperatures thus preventing thegrowth of airborne bacteria (Table 2) A day after the addition of all the ingredientsformation of a moist surface showing clear cracks occurs Furthermore the mashbegins to bubble (indication of fermentation progress) as gas is given off during theburgeoning fermentation The fermentation can take place at various temperaturesand its duration depends on it that is at lower temperatures it takes up to twoweeks but the sake aroma is much more appealing compared to that formed athigher temperatures The characteristic sake aroma results from combined flavor
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 19
Table 2 Quantities of Ingredients at Each Stage of Mixing the Main Mash (Moromi)
Yeast 1st 2nd 3rd 4thStarter (Moto) Addition Addition Addition Additiona Total
Total rice (kg) 210 470 850 1470 3000Steamed rice (kg) 140 330 650 1230 2350Koji rice (kg) 70 140 200 240 65030 Brewerrsquos 1200 1200
alcohol (L)Water (L) 230 420 1010 2030 360 405
aTraditional brewers mix the final mash in three stages The fourth addition of alcohol and wateris a controversial postwar development (Kondo 1984)
components of a number of compounds produced during fermentation (49) Theelevated alcohol content of the fermented sake is related to lipid metabolism ofyeast in the presence of proteolipid provided by the koji molds (5051)
Additions (CCP6)
The addition of alcohol at this stage is carried out unless it is clearly statedthat sake does not contain any alcohol from extraneous sources The added alcoholshould not contain methanol or if it does the content of the latter should be lessthan 05 gL because of its toxicity (CCP chemical hazard)
Pressing
Automatic machine presses (consisting of a series of panels with balloon-likesacks attached) are most widely used nowadays instead of the traditional time-consuming method using long bags The remained caked lees are employed forpickle production and cooking or sedimentation of rice particles may occur Alter-natively sedimentation of rice particles at the bottom of the tank may take place
Filtration
Coloring and aging (maturation) inhibition can be effected by using activatedcharcoal filters
Pasteurization (CCP7 and CCP8)
Heating sake preferably twice at 65C kills off the remaining yeast stops en-zyme action and deactivates the lactic acid bacteria that will eventually spoil sakeThis process represents a microbiological hazard for which the specific plant may
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ORDER REPRINTS
20 KOURTIS AND ARVANITOYANNIS
set CLs However in recent years refrigerated storage and transport have madeunpasteurized sake with characteristic aroma available to the consumer (43)
Dilution
The produced sake in its raw state (Genchu) contains more than 20 alcoholby volume but it is generally diluted to about 15ndash16 vol-
BottlingStorageDistribution
The applied procedures are similar to those mentioned for the beer productionA summary of the occurring hazards CCPs CLs and preventive and correc-
tive measures is given in Table 3
WINE
Introduction
Wines are made from the fruit of Vitis vinifera of which there are a greatnumber of varieties growing in many parts of the world The history of wine isinextricably interwoven with human history It might be as true to say that it waswith wine that civilization began for the vine takes longer to mature than any othercrop and does not produce grapes for wine making until its fourth year It is notexactly known when men first had wine but it was accepted as a gift from the godsthe Egyptians attributed it to Osiris and the Greeks to Dionysos Mesopotamia andthe Caucasian slopes were no doubt early sources of wine from where it was spreadto Egypt and Greece and then to the rest of the world (52)
Wine Main Production Stages
The main stages for wine production are schematically presented in Figure 5
Harvesting (CCP1)
Grape harvesting is a CCP comprising both physical and chemical hazardsPhysically the grapes should be sound without rotten parts otherwise oxidativeand microbial contamination can rapidly develop Therefore harvesting shouldbe conducted with the greatest possible care and an efficient disease managementsystem should be applied (5354) Pesticides play an important role in pest man-agement but they should be handled with care because they constitute chemicalhazards (55) At the time of harvest the grapes must have also reached the correctmaturity when Brix and Total Acidity (TA) levels indicate maturity of wine Sincepesticide and fungicide residues on the surface of the berries constitute chemical
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 21
hazards Oliva et al (56) proposed a rapid and simple gas chromatographic methodfor their determination The maximum residue limits for pesticides in grapes andwines are provided by Codex Alimentarius (45) and Organisation International duVin (57) Finally the bulk bins used for grapes transportation should be effectivelydecontaminated to avoid any microbial infection
Stemming
Stemming includes the removal of stem leaves and grape stalks before crush-ing This procedure has several advantages because the total volume of processedproduct drops by 30 thus resulting in smaller tanks and eventually increasingthe productrsquos alcoholic content (58) However the end of fermentation and the al-cohol content of finished product depend mostly on the Brix level of initial grapesStemmers usually contain a perforated cylinder allowing berries to pass throughbut prevent the passage of stems stalks and leaves
Crushing
Crushing typically immediately follows stemming since some crushing ofthe fruit occurs during stemming The released juice is highly susceptible to oxida-tive browning and microbial contamination The most common crushing processesinvolve pressing the fruit against a perforated wall or passing the fruit through a setof rollers It is very important to avoid crushing the seeds to preclude contaminat-ing the must with seed oils the oxidation of which could produce rancid odors andconstitute an undesirable source of bitter tannins Equally important is the properhandling of product because inappropriate timing might lead to a sudden startof alcoholic fermentation and consequently to higher fermentation temperatureswhile a delay might cause microbial contamination and oxidative browning (59)
Maceration
Maceration is the breakdown of grape solids after crushing of grapes Whilemaceration is always involved in the initial stage of red wine fermentation the long-standing trend has been to limit maceration in white wine production Temperatureand duration of maceration depend on grape and wine variety Usually for white androse wines the maceration time is less than 24 h red destined for early consumptionis macerated for 3ndash5 days and red for aging is macerated from 5 days to 3 weeksFermentation usually occurs during this or at the end of maceration The amount ofthe antimicrobial to be used usually added to white musts that are most sensitive tooxidation depends on the crop health and maceration temperature Sulfur dioxidehas a distinct advantage over other antimicrobial agents because of the relativeinsensitivity of the wine yeasts to its action However it is also toxic or inhibitoryto most bacteria and yeasts (ie Candida Pichia Hansenula) at low concentrations(60) and has a rather low retention capability after the clarification step (61)
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ORDER REPRINTS
22 KOURTIS AND ARVANITOYANNISTa
ble
3Su
mm
ary
ofH
azar
dsC
CPs
CL
sM
onito
ring
Cor
rect
ive
Act
ions
and
Pers
onne
lRes
pons
ible
for
Sake
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
a(M
CP
)bM
easu
res
CC
PPa
ram
eter
(CL
s)Pr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
CC
ertifi
edsu
pplie
rs
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
wat
er
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Cer
tified
supp
liers
Hea
vym
etal
spr
esen
cein
wat
er
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Eva
luat
ion
ofth
ede
cont
amin
atin
gm
etho
ds
MC
ertifi
edsu
pplie
rs
prop
erpr
epar
atio
n
Mic
robi
alco
ntam
inat
ion
ofth
ecu
lture
100
clea
nM
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Wat
erm
icro
biol
ogic
alqu
ality
Abs
ence
ofpa
thog
ens
Insp
ectio
nof
the
equi
pmen
t
Ric
epo
lishi
ng(C
CP2
)C
Cer
tified
supp
lier
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
polis
hed
rice
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Was
hing
(CC
P3)
PC
ertifi
edsu
pplie
rs
inst
alla
tion
ofau
tom
atic
sepa
rato
r
Ani
mal
impu
ritie
sO
ther
orga
nic
and
inor
gani
cm
ater
01
mm
15
mm
01
mm
Spec
ific
exam
inat
ion
Rew
ashi
ngof
spec
ific
batc
hch
ange
supp
lier
Qua
lity
cont
rol
man
ager
Stea
min
g(f
orun
past
euri
sed
sake
)(C
CP4
)
MG
MP
sche
dule
dm
icro
biol
ogic
alco
ntro
ls
Pres
ence
ofye
asts
and
LA
B
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Spec
ific
batc
hre
proc
essi
ng
CIP
stan
dar-
disa
tion
Qua
lity
cont
rol
man
ager
T
rain
ned
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 23
Ferm
enta
tion
(CC
P5)
CM
ater
ialc
ontr
ol
GM
Pco
rros
ion
chec
ks
Hea
vym
etal
pres
ence
Pest
icid
ere
sidu
es
Aslt
02
Cd
lt
001
Pb
lt
03
(mg
L)
Spec
ific
chem
ical
anal
ysis
Dem
etal
lisat
ion
Cha
nge
supp
lier
Rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
GM
Pus
eof
nont
oxic
glyc
ole
Res
idue
sof
ehty
lene
glyc
ole
ampde
terg
ents
0Sp
ecifi
cch
emic
alan
alys
isD
ilutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Alc
ohol
addi
tion
(CC
P6)
CC
ertifi
edsu
pplie
rM
etha
nolc
onte
ntlt
05
gL
GC
exam
inat
ion
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erPa
steu
riza
tion
(CC
P7amp
CC
P8)
MR
unni
ngof
past
euri
ser
acco
rdin
gto
prog
ram
Det
ectio
nof
yeas
tsL
AB
en
zym
atic
activ
ity
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Tem
pera
ture
adju
stm
ent
batc
hre
proc
essi
ng
prop
erm
achi
nery
disi
nfec
tion
Qua
lity
cont
rol
man
ager
Tech
nica
lm
anag
er
aR
egar
ding
the
proc
edur
esof
bottl
ing
stor
age
and
dist
ribu
tion
the
CC
Psar
esi
mila
rto
thos
em
entio
ned
inTa
ble
1fo
rbe
erpr
oduc
tion
bM
CP
stan
dfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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ORDER REPRINTS
26 KOURTIS AND ARVANITOYANNIS
Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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ORDER REPRINTS
28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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2011
ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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ORDER REPRINTS
34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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2011
ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
by [
Sule
yman
Dem
irel
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vers
itesi
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
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ecem
ber
2011
ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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irel
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itesi
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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ded
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yman
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irel
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itesi
] at
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ecem
ber
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
Dow
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ded
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yman
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irel
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vers
itesi
] at
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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ORDER REPRINTS
6 KOURTIS AND ARVANITOYANNIS
Tabl
e1
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rB
eer
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Mon
itori
ngC
orre
ctiv
eR
espo
nsib
lePr
oces
sSt
ep(P
MC
)aM
easu
res
CC
PPa
ram
eter
Cri
tical
Lim
itPr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
fung
ide
velo
pmen
tte
mpe
ratu
rean
dR
Hre
gula
tion
duri
ngst
orag
e
Myc
otox
inpr
oduc
tion
000
4m
gL
Vis
uali
nspe
ctio
nof
fung
ide
velo
pmen
tH
PLC
EL
ISA
E
PSan
alys
is
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
er
Cer
tified
supp
liers
sc
hedu
lein
spec
tions
Pres
ence
ofE
nter
o-ba
cter
iace
ae
0M
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Cha
nge
supp
lier
Stri
cktly
follo
win
gin
stru
ctio
nsC
onta
min
atio
nof
mic
robi
alpr
epar
atio
ns
100
clea
nC
hang
epr
epar
atio
nm
etho
dC
Effi
cien
tdis
ease
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
barl
eyh
ops
wat
er
By
pest
icid
eas
desc
ribe
dby
Cod
ex
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erC
ertifi
edsu
pplie
rsPr
oper
wat
erde
cont
amin
atio
nH
eavy
met
als
pres
ence
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Rej
ectio
nof
spec
ific
batc
hD
e-m
etal
lisat
ion
step
Use
ofde
ioni
ser
Wat
errsquos
elec
tric
alco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nise
r
Aut
omat
icdi
scon
tinua
tion
ofde
ioni
ser
anal
ysis
ofw
ater
sam
ples
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 7
Mal
ting
(CC
P2)
CU
seof
indi
rect
heat
ing
syst
ems
cont
roll
ow-N
Ox
burn
ers
ND
MA
prod
uctio
ndu
ring
kiln
ing
25
ppb
Con
tinuo
usch
ecki
ngth
ear
eas
peci
fican
alys
es
Rej
ectio
nor
mix
ing
with
othe
rba
tche
s
Qua
lity
cont
rol
man
ager
PC
ontr
olof
time
tem
pera
ture
and
RH
Col
our
and
flavo
urde
velo
pmen
tSp
ecifi
edby
part
icul
arpl
ant
Con
tinuo
usm
onito
ring
ofpr
oces
sing
cond
ition
s
Mix
ing
with
othe
rm
alts
rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
MPr
oper
hadl
ing
oper
atio
nsaf
ter
prod
uctio
n
Myc
otox
inpr
oduc
tion
000
4m
gL
Vis
uali
nspe
ctio
nof
fung
ide
velo
pmen
tH
PLC
EL
ISA
E
PSan
alys
is
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
er
Mas
hing
(CC
P3)
CC
ontr
olof
tem
pera
ture
CIP
ND
MA
prod
uctio
nde
terg
ent
resi
dues
25
ppb
Non
eC
ontin
uous
reco
rdin
gof
the
proc
essi
ng
Adj
ustl
aute
ring
prog
ram
Qua
lity
cont
rol
man
ager
Lau
teri
ng(C
CP4
)C
Sche
dule
Insp
ectio
nun
der
plat
ecl
eani
ng
AT
NC
lt20
ppb
Mic
robi
olog
ical
and
chem
ical
anal
yses
Prop
erm
aint
ain
re-l
aute
ring
ofth
eba
tch
Qua
lity
cont
rol
man
ager
Boi
ling
(CC
P5)
CC
orre
ctus
eof
boile
rtr
eatm
ent
chem
ical
s
Con
tam
inat
ion
with
dete
rgen
ts0
CIP
syst
emR
epai
rC
IPb
atch
reje
ctio
nQ
ualit
yco
ntro
lm
anag
erFe
rmen
tatio
n(C
CP6
)M
Aer
atio
nof
wor
tus
eof
yeas
tfor
max
6ge
nera
tions
Poor
yeas
tvi
abili
tyldquo
stuc
krdquofe
rmen
tatio
n
Min
90
viab
leye
astc
ell
Yea
stco
ncen
trat
ion
ferm
enta
bilit
yO
2co
ncen
trat
ion
inth
ew
ort
Incr
ease
prop
agat
ion
freq
uenc
yw
ort
aera
tion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
8 KOURTIS AND ARVANITOYANNIS
Tabl
e1
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Mon
itori
ngC
orre
ctiv
eR
espo
nsib
lePr
oces
sSt
ep(P
MC
)aM
easu
res
CC
PPa
ram
eter
Cri
tical
Lim
itPr
oced
ures
Act
ions
Pers
onne
l
Ferm
enta
tion
(CC
P6)
MIn
spec
tion
ofC
IPsy
stem
and
equi
pmen
t
Lac
toba
cill
iac
etic
acid
bact
eria
and
wil
dye
asts
Pres
ence
in1
mL
plat
e+1
mL
actid
ione
Plat
eco
unt
met
hod
ora
rapi
dde
tect
ion
met
hod
Prop
erdi
sinf
ectio
nof
equi
pmen
tre
proc
essi
ngof
the
batc
h
Qua
lity
cont
rol
man
ager
Filtr
atio
n(C
CP7
)C
Use
CO
2
prefi
lling
offil
ter
with
wat
er
O2
upta
kegt
02
ppm
diss
olve
dO
2
Mea
sure
men
tof
diss
olve
dO
2
Surv
eyof
filtr
atio
nfo
rin
crea
sed
O2
pick
up
Qua
lity
cont
rol
man
ager
Bot
tlec
anin
spec
tor
(CC
P8)
CG
MP
Cle
anin
gpe
rfor
man
ceN
oso
lids
noliq
uid
rem
nant
sE
labo
rate
elec
tron
icre
cogn
ition
syst
ems
afte
rC
IP
Rew
ashi
ngof
bottl
esC
IPsy
stem
insp
ectio
n
Qua
lity
cont
rol
man
ager
PC
ertifi
edsu
pplie
rpr
oper
hand
ling
ofbo
ttles
Bot
tles
prop
erfo
rfo
ods
and
drin
ks
bottl
esco
nditi
on
Cra
cks
scra
tche
sab
senc
eO
n-lin
evi
sual
cont
rol
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlec
anfil
ler
(CC
P9)
CIn
stal
latio
nof
cont
rolli
ngeq
uipm
ento
nth
eC
IPsy
stem
Con
tam
inat
ion
with
dete
rgen
tsC
ompl
ete
abse
nce
Org
anol
eptic
exam
inat
ion
offil
led
bottl
es
Bat
chre
ject
ion
Tra
ined
pers
onne
l
Bot
tlec
anse
aler
(CC
P10)
PC
orre
ctin
stal
latio
nof
equi
pmen
tB
low
-off
effe
ctO
ccur
renc
ere
duce
dto
anac
cept
able
leve
l
Con
trol
sets
ealin
gpr
essu
reA
utom
atic
rem
oval
ofde
stro
yed
bottl
es
Tra
ined
pers
onne
l
Bot
tlec
anpa
steu
riza
tion
(CC
P11)
PR
unni
ngpa
steu
rise
rac
cord
ing
topr
ogra
m
Oxi
datio
nca
used
ofw
rong
tem
pera
ture
-tim
ese
t
Max
65 C
for
20m
inq
uick
cool
ing
atth
eex
it
Con
tinuo
uson
-lin
etim
e-te
mpe
ratu
rech
ecki
ng
Adj
ust
tem
pera
ture
m
aint
ain
equi
pmen
t
Tech
nica
lm
anag
er
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 9
Bot
tlec
anin
spec
tion
(CC
P12)
PR
egul
arin
spec
tion
ofth
em
achi
nery
Phys
ical
dam
age
Occ
urre
nce
redu
ced
toan
acce
ptab
lele
vel
On-
line
mon
itori
ngE
quip
men
tst
anda
rdis
atio
nTe
chni
cal
man
ager
Lab
elin
g(C
CP1
3)P
Car
eful
sele
ctio
nof
the
etiq
uette
sM
ispl
aced
etiq
uette
sR
educ
edto
anac
cept
able
leve
lV
isua
lche
cks
cont
rolo
fth
eeq
uipm
ent
Rel
abel
ing
the
spec
ific
batc
hT
rain
edpe
rson
nel
Bot
tlec
anpa
ckag
ing
(CC
P14)
PC
orre
ctin
stal
latio
nof
the
equi
pmen
tB
ottle
sco
nditi
ondu
ring
palle
tisat
ion
Abs
ence
ofri
fts
inth
elu
tec
rack
orsc
ratc
hes
On-
line
visu
alco
ntro
lA
djus
tthe
equi
pmen
tpa
ram
eter
s(s
peed
pre
ssur
e)
Tech
nica
lm
anag
er
Stor
age
(CC
P15)
PC
ontr
olst
orag
eco
nditi
ons
Org
anol
eptic
cond
ition
ofbe
erSp
ecifi
edby
the
part
icul
arpl
ant
Sche
dule
dco
ntro
lsof
finis
hed
prod
uct
Adj
ustt
hest
oreh
ouse
cond
ition
s
Tra
ined
pers
onne
l
aP
MC
stan
dfo
rph
ysic
alm
icro
biol
ogic
alan
dch
emic
alha
zard
sre
spec
tivel
y
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2011
ORDER REPRINTS
10 KOURTIS AND ARVANITOYANNIS
than malt are sometimes used as an additional source of extract to supplementmalt Unmalted cereal adjuncts usually contain no active enzymes and thereforerely on malt or exogenous enzymes to provide the necessary enzymes for starchconversion (19)
Yeast growth cannot be separated from the fermentation process and it isnecessary to the production of both beer and fresh yeast for use in subsequentfermentations The quality control of yeasts comprises a) the selection maintenanceand supply of a suitable strain and b) the routine assessment of purity and detectionof microbial contamination (CCP) (20)
Malting (CCP2)
This process involves steeping the barley in a shallow bed of water at a tem-perature of 10ndash15C so that its moisture content amounts to 45 wt- of barleyBarley is then allowed to germinate under controlled temperature conditions atapproximately 15C and RH100 with constant turning to prevent matting therootlets The barleycorn undergoes germination through air passage via the germi-nating malt for 3ndash5 days Gentle heating stops germination due to moisture removaland promotes formation of flavor compounds The kiln temperature regime is cru-cial for the color of malt and the survival of enzymes to be used in the mashingprocess Kilning duration usually varies between 24 and 48 h Time temperatureand moisture content are varied to control color and flavor development Chemicalmicrobiological and physical hazards may be encountered in this step In partic-ular nitrosodimethylamine (NDMA) production during kilning (reaction of NOx
with organic materials) constitutes a chemical hazard with a critical limit (CL) at25 ppb because of its suspected carcinogenic effect In addition mycotoxin pro-duction more than 0004 mgL and color and flavor alteration represent chemicaland physical hazards respectively The NDMA content in malt can be controlled byusing indirect heating systems or by carefully maintained and controlled low-NOx
burners Regular checks should nevertheless be carried out by the maltster so thatthe residual risk caused by polluted air is kept as low as possible (17) The finishedmalt has its rootlets removed and is screened to produce the uniform quality Duringthe malting process two important changes occur a) the barley develops its ownenzyme systems and b) the naturally produced enzymes start to break down the cellstructure of the endosperm (19) Malt quality control tests include hot water extractcolor soluble nitrogen total nitrogen moisture enzyme activities viscosity andlautering prediction tests The microbiological status of malt used in the followingsteps (CCP) is very much dependent on its handling operations after production (16)
Milling
The main function of dry or wet milling is to reduce the malt particle sizeto form grist (ground or milled grain) The particle size reduction facilitates the
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 11
extraction of soluble components mainly sugars and nitrogenous compounds fromthe endosperm (21)
Mashing (CCP3)
Mashing the first step in wort production involves extracting soluble materi-als from the milled malt This is accomplished by feeding the grist through Steelrsquosmasher a hydrator consisting of a large-bore tube bent at right angles During itspassage through the vertical portion of tube the grist is spayed with hot water (typ-ically 65C) and then mixed with the help of a revolving screw (22) The floatingendosperm particles hydrate and undergo further amylolytic scission by α- andβ-amylases Processors adjust the pH and temperature conditions to allow bothenzymes with a range of susceptibility to pH and temperature to work effectivelyNDMA production (CL = 25 ppb) as well as possible detergent residues constitutepotential chemical hazards for public health Continuous monitoring at the process-ing and adjustment of the lautering program and Cleaning In Place (CIP) systemwhen deviation occurs are proper preventive and corrective actions respectively
Lautering (CCP4)
The lauter tun is a vessel normally rinsed thoroughly with a sparging or hotwater delivery system before receiving the mash which precipitates at the flat floorof slotted stainless steel or brass plates At tun center there is a lautering machineon the shaft of which rotating rakes are attached to facilitate draining the wortinto a collection vessel called grant The wort is recirculated through the lauter tununtil it reaches a certain degree of clarity whereupon it is delivered to the kettle(21) In lautering production of Apparent Total N-nitroso compounds (ATNC)above the CL of 20 ppb constitute a CCP that should be monitored with chemicaland microbiological analyses Scheduled inspection and under-plate cleaning canprevent insufficient separation of trub from wort (23)
Boiling (CCP5)
Wort is boiled for up to 2 h at atmospheric pressure following the additionof hops (CCP) The shape of copper boiling time and temperature can affect thequality of produced beer The major objectives of wort boiling are a) wort steril-ization and enzyme inactivation b) extraction of bitter and other substances fromhops and formation of flavor compounds and c) evaporation of excess water andwort concentration evaporation of undesirable flavour volatiles Wort contamina-tion of the wort with Enterobacteriaceae from hops can result in various off-flavorsincluding ldquovegetablerdquo and ldquophenolicrdquo taints (24) Correct use of boiler treatmentchemicals steam condensate tasting for carrying over the taints and operation of
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ORDER REPRINTS
12 KOURTIS AND ARVANITOYANNIS
phenol analyses are all essential to avoid chemical contamination and taints devel-opment (23)
Clarification
Wort clarification is conducted either through sedimentation or filtrationWhen whole hop cones are used it is necessary to employ either a hop back ora hop separatorndashfilter The drop in hop usage and the widespread acceptance ofpreisomerized extracts led to utilization of a vertical cylinder known as whirlpoolwhich induces sustainable circulation of the trub collecting as a compact cone in thebase Whirlpools are more suited to larger worts and can also be used with ale Inmodern breweries centrifuges constitute a promising alternative to whirlpools (25)
Cooling
To prepare for fermentation the clear hopped wort is cooled usually in aplate heat exchanger During cooling it is advisable to aerate or even to oxygenatethe wort because next processing step involves yeast growth promoted in the pres-ence of dissolved oxygen despite the low dissolved oxygen concentration in wort(7ndash14 ppm) (22)
Fermentation (CCP6)
Fermentation aims at producing ethanol by fermenting yeasts Yeasts vary intheir behavior during fermentation some strains tend to flocculate trap plug CO2 andrising to the top whereas others do not flocculate and precipitate Several lagers areproduced by bottom fermentation while many types of ales and stouts are producedby top fermentation Saccharomyces cerevisiae is usually the top fermenting yeastin the range of 18ndash22C whilst the bottom-fermenting are strains of Saccharomycesuvarum that function in the range of 7ndash15C (26) Therefore the temperature atwhich fermentation occurs is very crucial for the further stages of beer productionThe modern use of cylindroconical vessels has reduced the fermentation periodfor ales and lagers from 7 to 2 or 3 days and from 10 to 7 days respectively (27)Fermentation is monitored by taking samples for measuring the specific gravityand can be controlled by varying the cooling rate (20) ldquoStuckrdquo fermentation wherethe required ethanol level is not attained and microbial contamination with Lacticacid bacteria mainly Lactobacilii and Pediococcus which cause taints duringmaturation or in bottle storage (28) represent microbiological hazards which arethe only hazard detected at this stage Common causes for ldquostuckrdquo fermentationinclude premature yeast flocculation and yeast failure to metabolize maltotriosedue to repression by glucose (25) A minimum of 90 viable yeast cells (CL) canbe applied to ensure the development of the process During fermentation the pH
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 13
drops from 52 to 42 and by its completion the yeast is removed either as a top orbottom crop and retained to pitch the next fermentation Apart from the conventionalmicrobial detection methods with plate count several rapid detection methodspotentially applied in breweries such as ATP bioluminescence flow cytometryand polymerase chain reaction have been developed to reduce the incubation timefrom 3ndash4 days to 1ndash2 (2930)
Maturation
Maturation includes all those changes occurring between the end of primaryfermentation to beer filtration (31) Ale is matured at relatively warm temperatures12ndash20C while lagers are held under much cooler conditions The warmer temper-atures allow the rapid metabolism of any residual and priming sugars as well asloss of green flavors within 1ndash2 weeks depending on beer type yeast strain wortcomposition and primary fermentation conditions In case of lager the beer used tobe held at refrigerated temperatures for up to several months after fermentation al-lowing formation of proteintannin complexes (18) Today the enzyme addition hassubstantially shortened this process to several weeks during which flavor maturesEnzymes such as papain may be added during transfer between fermentation andmaturation tank The dosage of the proteolytic enzyme varies depending on typeof beer and process Enzyme activity decreases progressively during maturationuntil its inactivation with pasteurization Part of the enzyme absorbed in the yeastsurface is removed during filtration (19)
Filtration (CCP7)
Beer produced during fermentation is turbid and should be clarified prior to itsmarketing This turbidity is due to the presence of yeasts and proteinaceous materi-als associated with carbohydrates and polyphenols The formation of these proteinprecipitates is attributed to cold temperature low pH and poor solubility in alcoholicsolutions (32) To prevent this from occurring in the final product the beer may besubjected to various chill-proofing treatments during its storage These treatmentsgenerally include the addition of clays to absorb the colloidal materials or prote-olytic enzymes used to further solubilize the protein fraction (33) Since oxygenuptake during this process could severely affect the product organoleptic charac-teristics a CCP of dissolved oxygen should be applied with a CL of 02 ppm (34)
Packaging and Sealing
The packing section comprises several CCPs including the containers to beused their cleaning and disinfection (CCP8) the filler line (CCP9) and the sealer(CCP10) The bursting pressure of the bottles as guaranteed by the manufacturerin his specifications for the new glass may no longer be valid in case of reusable
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14 KOURTIS AND ARVANITOYANNIS
bottles due to the considerable physical stress during already exerted upon themduring the filling process Insufficient cleaning of reusable bottles due to low temper-atures and concentrations of the employed cleaning solutions as well as presence ofextraneous entrapped materials within bottles and improper emptying consist pos-sible hazards Moreover cleaning solution remnants and shards introduced throughthe procedure pose problems under working conditions The beer filler may be con-taminated by cleaning and disinfection solutions Contamination sources may bedue to inadequate pressure or faulty CIP system resulting in cleaning and disinfect-ing solution remains in the pressure tank or the ring bowl of the filler (3536) Thecrown corker should be correctly installed the filling pressure of bottle caps on themouths of the bottles should be adjusted to ensure a specified blow-off effect toavoid bottle bursting After filling there should be a full bottle inspector detectingglass particles in bottles or possible leakage (37)
Bottle Pasteurization (CCP11)
Pasteurization is carried out to ensure the beer shelf life over a period ofmonths This is accomplished by the development of tunnel pasteurization in whichthe beer bottle is subjected to 60C for 20 min Over-pasteurization which causesoxidation and can adversely affect beer flavor (38) is a potential physical hazardFurthermore it is crucial to check the time-temperature procedure with adequatecorrective actions for assuring the production of a satisfactory product
Bottle Inspection (CCP12)
Bottle inspection after the pasteurization step is important to ensure that bottleshave not been damaged during the process (39) Should such a situation occur theequipment has to be standardized by the production engineer
Labeling and Standardization (CCP13)
Labeling of the package should comply with the requirements of the CodexGeneral for the labeling of prepackaged foods (40) This means that the name of theproduct shall be clearly declared there must be a list of ingredients in descendingorder of proportion no other fruit may be represented pictorially except those usedand ldquothe date of minimum durabilityrdquo will be declared by the month and year inuncoded numerical sequence
BottleCan Packaging (CCP14)
Bottles (cans) are packaged into paperboard boxes of various sizes accordingto the bottle or can dimensions The encountered hazards can be of physical natureconcerning the bottles (cans) condition during the procedure
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 15
Storage (CCP15)
The finished beer undergoes chemical microbiological and organoleptic anal-ysis to ensure that its properties are within its specification range A synoptical pre-sentation of the occurring hazards CCPs CLs and preventive corrective measuresis given in Table 1
SAKE
Introduction
Sake is a fermented liquor made from rice and coming in many varietiesdepending on the raw materials manufacturing process and process after brewing(41) According to the earliest records sake was originally brewed from rice thathad been chewed to reach saccharification followed by natural fermentation Sakebrewed this way was used as a sacred wine in the worship of the Shinto gods Thisassociation with religion Shintoism and Buddhism has caused a deep intertwiningof sake with the traditions and social customs of Japan Thus today sake is servedat ceremonies and celebrations of all kinds (42) Sake has the highest alcoholpercentage by volume of any fermented beverage In its natural undiluted state itmay contain a potent 20 ethanol compared to 3ndash5 for beer or 9ndash12 for winewhich may reach higher values for fortified wines (4344) The central brewersrsquounion divides sake into four basic flavor types on four axes of sweet sour bitterand umai The latter is another translatorrsquos nightmare which generally ends uptranslated as delicious According to position established along these axes sakeis considered to be of ldquomature typerdquo ldquofragrant typerdquo ldquolight and smooth typerdquo orldquofull-bodied typerdquo (Fig 3) However no set of criteria can adequately express themultiplicity of sensations that together create the flavor unique to any individualsake but there is a perceived need for terms which quickly and simply give thegeneral idea
Figure 3 Main flavor types for sake characterization (43)
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16 KOURTIS AND ARVANITOYANNIS
Sake Main Production Stages
The main stages for sake production are schematically presented in Figure 4
Raw Materials (CCP1)
The main ingredients of Japanese sake are rice sake rice sake yeastand water The rice most suitable for sake should consist of large grains and shouldbe soft with a white part at its center due to coarse cell structure Rice should complywith the maximum residue limits for pesticides and insecticides established by theCodex Alimentarius Commission for this commodity (45) (CCP chemical hazard)For Japanese sake yellow koji mold (Aspergillus oryzae) is used Sake yeast (Sac-charomyces cerevisiae) is a microbe converting the occurring glucose and mineralsin rice and water into alcohol Employment of bubble-free type yeast eliminates
Figure 4 Process flow diagram of sake production (264647)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 17
the bubble removal step thus shortening the brewing period and reducing the costShould the factory wish to employ a specific yeast an adequate disinfection ofthe building interior is required otherwise undesirable bacteria may be introducedwhich could prove hazardous to human health (CCP microbiological hazard) (46)
Rice Polishing (CCP2)
The brown rice used for sake production must be first polished to remove theouter portion of the grain which contains fats proteins minerals and amino acidsthat can cause unpleasant flavors leaving the starch residues that are located in thecenter of the grain Nowadays machines are programmed to automatically removewhatever portion of the rice is required for the specific sake (47) The rice polishingratio (73ndash35) is expressed by the following formula (43)
Rice polishing ratio=(weight of white riceweight of brown rice)times100 (1)
The polishing process should be gently carried out because friction results inheat generation thereby greatly affecting water absorption and rice grain structureBroken grains are unlikely to satisfactorily ferment (47) Maybe the most importantstage in sake production consists of yeast starter mash production which can takeplace either with the classical Kimoto or slightly revised Yamahai process or withthe new ldquohigh speedrdquo methods (48)
Washing (CCP3)
After the rice has been polished rice powder clinging to the grain surface isremoved by washing Washing can be carried out either mechanically or manually(laborious hand washing) and should result in removing most of the organic andinorganic impurities reaching the CLs set by Codex Alimentarius of 15 and01 mm respectively
Soaking (Steeping)
Soaking allows rice to absorb the desired amount of water that is crucial toestablishing the rice consistency For sake produced ldquoen masserdquo simply dumpinginto a vat overnight for as long as 14 h is a usual case (47) However high polishedrice may be soaked within minutes In such a case an error of a minute might proveto have dire consequences for the end product (43)
Steaming (CCP4)
Steaming aims at softening the rice grains and breaking down the starchmolecules thus encouraging the growth of Aspergillus oryzae and eliminating all
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18 KOURTIS AND ARVANITOYANNIS
other microorganisms leaving an initially sterile environment prone to sake moldpropagation Presence of lactic acid bacteria (LAB) and yeasts may occur at theend of this step representing a microbiological hazard and resulting in consider-able organoleptic losses The time can vary from 20 to 60 min depending on thebrewer and apparatus employed (40ndash60 and 20 min for traditional and automatedrespectively) (4346)
Cooling
The ensuing division of steamed rice is mainly related to its further use Apart of it is directly cooled by air blower whereas 20ndash30 is transferred to a heatedculture room to be infected with bacteria spores (Aspergillus oryzae) for sake moldproduction
Koji
Since rice grains contain no sugar it is the action of koji mold that converts thestarch in the grains to sugar The steamed rice is first cooled to 15ndash36C before beingtransferred to the koji culture room (30C) Spores of the mold are sprinkled likefine dust on the rice when it has cooled down to 33C After the spores are kneadedinto the steamed rice the rice is heaped and wrapped in cloths to prevent heat andmoisture loss which are two crucial factors for satisfactory bacterial growth Tomaintain uniform temperature and moisture rice is spread and mixed twice the firsttime after 20 hours (upon the appearance of white flecks) and then 7ndash8 h thereafteraccompanied by a distinctive aroma release (48)
Main Mash (Moromi) and Fermentation (CCP5)
In fermentation the occurring chemical hazards are related to heavy metalspresence (As lt 02 Cd lt 001 Pb lt 03 mgL) pesticide residues (as mentionedin Codex Alimentarius) and residues of detergents (absence) and ethylene glycole(absence) Their CLs can be determined and monitored with specific chemicalanalyses The ingredients of main mash (water koji rice and steamed rice) areadded to the starter mash in three steps (moving from small to bigger recipient)over a period of 4 days at successively lower temperatures thus preventing thegrowth of airborne bacteria (Table 2) A day after the addition of all the ingredientsformation of a moist surface showing clear cracks occurs Furthermore the mashbegins to bubble (indication of fermentation progress) as gas is given off during theburgeoning fermentation The fermentation can take place at various temperaturesand its duration depends on it that is at lower temperatures it takes up to twoweeks but the sake aroma is much more appealing compared to that formed athigher temperatures The characteristic sake aroma results from combined flavor
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 19
Table 2 Quantities of Ingredients at Each Stage of Mixing the Main Mash (Moromi)
Yeast 1st 2nd 3rd 4thStarter (Moto) Addition Addition Addition Additiona Total
Total rice (kg) 210 470 850 1470 3000Steamed rice (kg) 140 330 650 1230 2350Koji rice (kg) 70 140 200 240 65030 Brewerrsquos 1200 1200
alcohol (L)Water (L) 230 420 1010 2030 360 405
aTraditional brewers mix the final mash in three stages The fourth addition of alcohol and wateris a controversial postwar development (Kondo 1984)
components of a number of compounds produced during fermentation (49) Theelevated alcohol content of the fermented sake is related to lipid metabolism ofyeast in the presence of proteolipid provided by the koji molds (5051)
Additions (CCP6)
The addition of alcohol at this stage is carried out unless it is clearly statedthat sake does not contain any alcohol from extraneous sources The added alcoholshould not contain methanol or if it does the content of the latter should be lessthan 05 gL because of its toxicity (CCP chemical hazard)
Pressing
Automatic machine presses (consisting of a series of panels with balloon-likesacks attached) are most widely used nowadays instead of the traditional time-consuming method using long bags The remained caked lees are employed forpickle production and cooking or sedimentation of rice particles may occur Alter-natively sedimentation of rice particles at the bottom of the tank may take place
Filtration
Coloring and aging (maturation) inhibition can be effected by using activatedcharcoal filters
Pasteurization (CCP7 and CCP8)
Heating sake preferably twice at 65C kills off the remaining yeast stops en-zyme action and deactivates the lactic acid bacteria that will eventually spoil sakeThis process represents a microbiological hazard for which the specific plant may
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ORDER REPRINTS
20 KOURTIS AND ARVANITOYANNIS
set CLs However in recent years refrigerated storage and transport have madeunpasteurized sake with characteristic aroma available to the consumer (43)
Dilution
The produced sake in its raw state (Genchu) contains more than 20 alcoholby volume but it is generally diluted to about 15ndash16 vol-
BottlingStorageDistribution
The applied procedures are similar to those mentioned for the beer productionA summary of the occurring hazards CCPs CLs and preventive and correc-
tive measures is given in Table 3
WINE
Introduction
Wines are made from the fruit of Vitis vinifera of which there are a greatnumber of varieties growing in many parts of the world The history of wine isinextricably interwoven with human history It might be as true to say that it waswith wine that civilization began for the vine takes longer to mature than any othercrop and does not produce grapes for wine making until its fourth year It is notexactly known when men first had wine but it was accepted as a gift from the godsthe Egyptians attributed it to Osiris and the Greeks to Dionysos Mesopotamia andthe Caucasian slopes were no doubt early sources of wine from where it was spreadto Egypt and Greece and then to the rest of the world (52)
Wine Main Production Stages
The main stages for wine production are schematically presented in Figure 5
Harvesting (CCP1)
Grape harvesting is a CCP comprising both physical and chemical hazardsPhysically the grapes should be sound without rotten parts otherwise oxidativeand microbial contamination can rapidly develop Therefore harvesting shouldbe conducted with the greatest possible care and an efficient disease managementsystem should be applied (5354) Pesticides play an important role in pest man-agement but they should be handled with care because they constitute chemicalhazards (55) At the time of harvest the grapes must have also reached the correctmaturity when Brix and Total Acidity (TA) levels indicate maturity of wine Sincepesticide and fungicide residues on the surface of the berries constitute chemical
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 21
hazards Oliva et al (56) proposed a rapid and simple gas chromatographic methodfor their determination The maximum residue limits for pesticides in grapes andwines are provided by Codex Alimentarius (45) and Organisation International duVin (57) Finally the bulk bins used for grapes transportation should be effectivelydecontaminated to avoid any microbial infection
Stemming
Stemming includes the removal of stem leaves and grape stalks before crush-ing This procedure has several advantages because the total volume of processedproduct drops by 30 thus resulting in smaller tanks and eventually increasingthe productrsquos alcoholic content (58) However the end of fermentation and the al-cohol content of finished product depend mostly on the Brix level of initial grapesStemmers usually contain a perforated cylinder allowing berries to pass throughbut prevent the passage of stems stalks and leaves
Crushing
Crushing typically immediately follows stemming since some crushing ofthe fruit occurs during stemming The released juice is highly susceptible to oxida-tive browning and microbial contamination The most common crushing processesinvolve pressing the fruit against a perforated wall or passing the fruit through a setof rollers It is very important to avoid crushing the seeds to preclude contaminat-ing the must with seed oils the oxidation of which could produce rancid odors andconstitute an undesirable source of bitter tannins Equally important is the properhandling of product because inappropriate timing might lead to a sudden startof alcoholic fermentation and consequently to higher fermentation temperatureswhile a delay might cause microbial contamination and oxidative browning (59)
Maceration
Maceration is the breakdown of grape solids after crushing of grapes Whilemaceration is always involved in the initial stage of red wine fermentation the long-standing trend has been to limit maceration in white wine production Temperatureand duration of maceration depend on grape and wine variety Usually for white androse wines the maceration time is less than 24 h red destined for early consumptionis macerated for 3ndash5 days and red for aging is macerated from 5 days to 3 weeksFermentation usually occurs during this or at the end of maceration The amount ofthe antimicrobial to be used usually added to white musts that are most sensitive tooxidation depends on the crop health and maceration temperature Sulfur dioxidehas a distinct advantage over other antimicrobial agents because of the relativeinsensitivity of the wine yeasts to its action However it is also toxic or inhibitoryto most bacteria and yeasts (ie Candida Pichia Hansenula) at low concentrations(60) and has a rather low retention capability after the clarification step (61)
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22 KOURTIS AND ARVANITOYANNISTa
ble
3Su
mm
ary
ofH
azar
dsC
CPs
CL
sM
onito
ring
Cor
rect
ive
Act
ions
and
Pers
onne
lRes
pons
ible
for
Sake
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
a(M
CP
)bM
easu
res
CC
PPa
ram
eter
(CL
s)Pr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
CC
ertifi
edsu
pplie
rs
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
wat
er
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Cer
tified
supp
liers
Hea
vym
etal
spr
esen
cein
wat
er
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Eva
luat
ion
ofth
ede
cont
amin
atin
gm
etho
ds
MC
ertifi
edsu
pplie
rs
prop
erpr
epar
atio
n
Mic
robi
alco
ntam
inat
ion
ofth
ecu
lture
100
clea
nM
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Wat
erm
icro
biol
ogic
alqu
ality
Abs
ence
ofpa
thog
ens
Insp
ectio
nof
the
equi
pmen
t
Ric
epo
lishi
ng(C
CP2
)C
Cer
tified
supp
lier
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
polis
hed
rice
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Was
hing
(CC
P3)
PC
ertifi
edsu
pplie
rs
inst
alla
tion
ofau
tom
atic
sepa
rato
r
Ani
mal
impu
ritie
sO
ther
orga
nic
and
inor
gani
cm
ater
01
mm
15
mm
01
mm
Spec
ific
exam
inat
ion
Rew
ashi
ngof
spec
ific
batc
hch
ange
supp
lier
Qua
lity
cont
rol
man
ager
Stea
min
g(f
orun
past
euri
sed
sake
)(C
CP4
)
MG
MP
sche
dule
dm
icro
biol
ogic
alco
ntro
ls
Pres
ence
ofye
asts
and
LA
B
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Spec
ific
batc
hre
proc
essi
ng
CIP
stan
dar-
disa
tion
Qua
lity
cont
rol
man
ager
T
rain
ned
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 23
Ferm
enta
tion
(CC
P5)
CM
ater
ialc
ontr
ol
GM
Pco
rros
ion
chec
ks
Hea
vym
etal
pres
ence
Pest
icid
ere
sidu
es
Aslt
02
Cd
lt
001
Pb
lt
03
(mg
L)
Spec
ific
chem
ical
anal
ysis
Dem
etal
lisat
ion
Cha
nge
supp
lier
Rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
GM
Pus
eof
nont
oxic
glyc
ole
Res
idue
sof
ehty
lene
glyc
ole
ampde
terg
ents
0Sp
ecifi
cch
emic
alan
alys
isD
ilutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Alc
ohol
addi
tion
(CC
P6)
CC
ertifi
edsu
pplie
rM
etha
nolc
onte
ntlt
05
gL
GC
exam
inat
ion
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erPa
steu
riza
tion
(CC
P7amp
CC
P8)
MR
unni
ngof
past
euri
ser
acco
rdin
gto
prog
ram
Det
ectio
nof
yeas
tsL
AB
en
zym
atic
activ
ity
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Tem
pera
ture
adju
stm
ent
batc
hre
proc
essi
ng
prop
erm
achi
nery
disi
nfec
tion
Qua
lity
cont
rol
man
ager
Tech
nica
lm
anag
er
aR
egar
ding
the
proc
edur
esof
bottl
ing
stor
age
and
dist
ribu
tion
the
CC
Psar
esi
mila
rto
thos
em
entio
ned
inTa
ble
1fo
rbe
erpr
oduc
tion
bM
CP
stan
dfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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26 KOURTIS AND ARVANITOYANNIS
Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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ORDER REPRINTS
28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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ORDER REPRINTS
34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
by [
Sule
yman
Dem
irel
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vers
itesi
] at
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ber
2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
nloa
ded
by [
Sule
yman
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irel
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vers
itesi
] at
09
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ber
2011
ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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irel
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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ded
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yman
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irel
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itesi
] at
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2011
ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
Dow
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ded
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yman
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irel
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itesi
] at
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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ded
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ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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ded
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yman
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irel
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itesi
] at
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ber
2011
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 7
Mal
ting
(CC
P2)
CU
seof
indi
rect
heat
ing
syst
ems
cont
roll
ow-N
Ox
burn
ers
ND
MA
prod
uctio
ndu
ring
kiln
ing
25
ppb
Con
tinuo
usch
ecki
ngth
ear
eas
peci
fican
alys
es
Rej
ectio
nor
mix
ing
with
othe
rba
tche
s
Qua
lity
cont
rol
man
ager
PC
ontr
olof
time
tem
pera
ture
and
RH
Col
our
and
flavo
urde
velo
pmen
tSp
ecifi
edby
part
icul
arpl
ant
Con
tinuo
usm
onito
ring
ofpr
oces
sing
cond
ition
s
Mix
ing
with
othe
rm
alts
rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
MPr
oper
hadl
ing
oper
atio
nsaf
ter
prod
uctio
n
Myc
otox
inpr
oduc
tion
000
4m
gL
Vis
uali
nspe
ctio
nof
fung
ide
velo
pmen
tH
PLC
EL
ISA
E
PSan
alys
is
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
er
Mas
hing
(CC
P3)
CC
ontr
olof
tem
pera
ture
CIP
ND
MA
prod
uctio
nde
terg
ent
resi
dues
25
ppb
Non
eC
ontin
uous
reco
rdin
gof
the
proc
essi
ng
Adj
ustl
aute
ring
prog
ram
Qua
lity
cont
rol
man
ager
Lau
teri
ng(C
CP4
)C
Sche
dule
Insp
ectio
nun
der
plat
ecl
eani
ng
AT
NC
lt20
ppb
Mic
robi
olog
ical
and
chem
ical
anal
yses
Prop
erm
aint
ain
re-l
aute
ring
ofth
eba
tch
Qua
lity
cont
rol
man
ager
Boi
ling
(CC
P5)
CC
orre
ctus
eof
boile
rtr
eatm
ent
chem
ical
s
Con
tam
inat
ion
with
dete
rgen
ts0
CIP
syst
emR
epai
rC
IPb
atch
reje
ctio
nQ
ualit
yco
ntro
lm
anag
erFe
rmen
tatio
n(C
CP6
)M
Aer
atio
nof
wor
tus
eof
yeas
tfor
max
6ge
nera
tions
Poor
yeas
tvi
abili
tyldquo
stuc
krdquofe
rmen
tatio
n
Min
90
viab
leye
astc
ell
Yea
stco
ncen
trat
ion
ferm
enta
bilit
yO
2co
ncen
trat
ion
inth
ew
ort
Incr
ease
prop
agat
ion
freq
uenc
yw
ort
aera
tion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
8 KOURTIS AND ARVANITOYANNIS
Tabl
e1
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Mon
itori
ngC
orre
ctiv
eR
espo
nsib
lePr
oces
sSt
ep(P
MC
)aM
easu
res
CC
PPa
ram
eter
Cri
tical
Lim
itPr
oced
ures
Act
ions
Pers
onne
l
Ferm
enta
tion
(CC
P6)
MIn
spec
tion
ofC
IPsy
stem
and
equi
pmen
t
Lac
toba
cill
iac
etic
acid
bact
eria
and
wil
dye
asts
Pres
ence
in1
mL
plat
e+1
mL
actid
ione
Plat
eco
unt
met
hod
ora
rapi
dde
tect
ion
met
hod
Prop
erdi
sinf
ectio
nof
equi
pmen
tre
proc
essi
ngof
the
batc
h
Qua
lity
cont
rol
man
ager
Filtr
atio
n(C
CP7
)C
Use
CO
2
prefi
lling
offil
ter
with
wat
er
O2
upta
kegt
02
ppm
diss
olve
dO
2
Mea
sure
men
tof
diss
olve
dO
2
Surv
eyof
filtr
atio
nfo
rin
crea
sed
O2
pick
up
Qua
lity
cont
rol
man
ager
Bot
tlec
anin
spec
tor
(CC
P8)
CG
MP
Cle
anin
gpe
rfor
man
ceN
oso
lids
noliq
uid
rem
nant
sE
labo
rate
elec
tron
icre
cogn
ition
syst
ems
afte
rC
IP
Rew
ashi
ngof
bottl
esC
IPsy
stem
insp
ectio
n
Qua
lity
cont
rol
man
ager
PC
ertifi
edsu
pplie
rpr
oper
hand
ling
ofbo
ttles
Bot
tles
prop
erfo
rfo
ods
and
drin
ks
bottl
esco
nditi
on
Cra
cks
scra
tche
sab
senc
eO
n-lin
evi
sual
cont
rol
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlec
anfil
ler
(CC
P9)
CIn
stal
latio
nof
cont
rolli
ngeq
uipm
ento
nth
eC
IPsy
stem
Con
tam
inat
ion
with
dete
rgen
tsC
ompl
ete
abse
nce
Org
anol
eptic
exam
inat
ion
offil
led
bottl
es
Bat
chre
ject
ion
Tra
ined
pers
onne
l
Bot
tlec
anse
aler
(CC
P10)
PC
orre
ctin
stal
latio
nof
equi
pmen
tB
low
-off
effe
ctO
ccur
renc
ere
duce
dto
anac
cept
able
leve
l
Con
trol
sets
ealin
gpr
essu
reA
utom
atic
rem
oval
ofde
stro
yed
bottl
es
Tra
ined
pers
onne
l
Bot
tlec
anpa
steu
riza
tion
(CC
P11)
PR
unni
ngpa
steu
rise
rac
cord
ing
topr
ogra
m
Oxi
datio
nca
used
ofw
rong
tem
pera
ture
-tim
ese
t
Max
65 C
for
20m
inq
uick
cool
ing
atth
eex
it
Con
tinuo
uson
-lin
etim
e-te
mpe
ratu
rech
ecki
ng
Adj
ust
tem
pera
ture
m
aint
ain
equi
pmen
t
Tech
nica
lm
anag
er
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 9
Bot
tlec
anin
spec
tion
(CC
P12)
PR
egul
arin
spec
tion
ofth
em
achi
nery
Phys
ical
dam
age
Occ
urre
nce
redu
ced
toan
acce
ptab
lele
vel
On-
line
mon
itori
ngE
quip
men
tst
anda
rdis
atio
nTe
chni
cal
man
ager
Lab
elin
g(C
CP1
3)P
Car
eful
sele
ctio
nof
the
etiq
uette
sM
ispl
aced
etiq
uette
sR
educ
edto
anac
cept
able
leve
lV
isua
lche
cks
cont
rolo
fth
eeq
uipm
ent
Rel
abel
ing
the
spec
ific
batc
hT
rain
edpe
rson
nel
Bot
tlec
anpa
ckag
ing
(CC
P14)
PC
orre
ctin
stal
latio
nof
the
equi
pmen
tB
ottle
sco
nditi
ondu
ring
palle
tisat
ion
Abs
ence
ofri
fts
inth
elu
tec
rack
orsc
ratc
hes
On-
line
visu
alco
ntro
lA
djus
tthe
equi
pmen
tpa
ram
eter
s(s
peed
pre
ssur
e)
Tech
nica
lm
anag
er
Stor
age
(CC
P15)
PC
ontr
olst
orag
eco
nditi
ons
Org
anol
eptic
cond
ition
ofbe
erSp
ecifi
edby
the
part
icul
arpl
ant
Sche
dule
dco
ntro
lsof
finis
hed
prod
uct
Adj
ustt
hest
oreh
ouse
cond
ition
s
Tra
ined
pers
onne
l
aP
MC
stan
dfo
rph
ysic
alm
icro
biol
ogic
alan
dch
emic
alha
zard
sre
spec
tivel
y
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2011
ORDER REPRINTS
10 KOURTIS AND ARVANITOYANNIS
than malt are sometimes used as an additional source of extract to supplementmalt Unmalted cereal adjuncts usually contain no active enzymes and thereforerely on malt or exogenous enzymes to provide the necessary enzymes for starchconversion (19)
Yeast growth cannot be separated from the fermentation process and it isnecessary to the production of both beer and fresh yeast for use in subsequentfermentations The quality control of yeasts comprises a) the selection maintenanceand supply of a suitable strain and b) the routine assessment of purity and detectionof microbial contamination (CCP) (20)
Malting (CCP2)
This process involves steeping the barley in a shallow bed of water at a tem-perature of 10ndash15C so that its moisture content amounts to 45 wt- of barleyBarley is then allowed to germinate under controlled temperature conditions atapproximately 15C and RH100 with constant turning to prevent matting therootlets The barleycorn undergoes germination through air passage via the germi-nating malt for 3ndash5 days Gentle heating stops germination due to moisture removaland promotes formation of flavor compounds The kiln temperature regime is cru-cial for the color of malt and the survival of enzymes to be used in the mashingprocess Kilning duration usually varies between 24 and 48 h Time temperatureand moisture content are varied to control color and flavor development Chemicalmicrobiological and physical hazards may be encountered in this step In partic-ular nitrosodimethylamine (NDMA) production during kilning (reaction of NOx
with organic materials) constitutes a chemical hazard with a critical limit (CL) at25 ppb because of its suspected carcinogenic effect In addition mycotoxin pro-duction more than 0004 mgL and color and flavor alteration represent chemicaland physical hazards respectively The NDMA content in malt can be controlled byusing indirect heating systems or by carefully maintained and controlled low-NOx
burners Regular checks should nevertheless be carried out by the maltster so thatthe residual risk caused by polluted air is kept as low as possible (17) The finishedmalt has its rootlets removed and is screened to produce the uniform quality Duringthe malting process two important changes occur a) the barley develops its ownenzyme systems and b) the naturally produced enzymes start to break down the cellstructure of the endosperm (19) Malt quality control tests include hot water extractcolor soluble nitrogen total nitrogen moisture enzyme activities viscosity andlautering prediction tests The microbiological status of malt used in the followingsteps (CCP) is very much dependent on its handling operations after production (16)
Milling
The main function of dry or wet milling is to reduce the malt particle sizeto form grist (ground or milled grain) The particle size reduction facilitates the
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 11
extraction of soluble components mainly sugars and nitrogenous compounds fromthe endosperm (21)
Mashing (CCP3)
Mashing the first step in wort production involves extracting soluble materi-als from the milled malt This is accomplished by feeding the grist through Steelrsquosmasher a hydrator consisting of a large-bore tube bent at right angles During itspassage through the vertical portion of tube the grist is spayed with hot water (typ-ically 65C) and then mixed with the help of a revolving screw (22) The floatingendosperm particles hydrate and undergo further amylolytic scission by α- andβ-amylases Processors adjust the pH and temperature conditions to allow bothenzymes with a range of susceptibility to pH and temperature to work effectivelyNDMA production (CL = 25 ppb) as well as possible detergent residues constitutepotential chemical hazards for public health Continuous monitoring at the process-ing and adjustment of the lautering program and Cleaning In Place (CIP) systemwhen deviation occurs are proper preventive and corrective actions respectively
Lautering (CCP4)
The lauter tun is a vessel normally rinsed thoroughly with a sparging or hotwater delivery system before receiving the mash which precipitates at the flat floorof slotted stainless steel or brass plates At tun center there is a lautering machineon the shaft of which rotating rakes are attached to facilitate draining the wortinto a collection vessel called grant The wort is recirculated through the lauter tununtil it reaches a certain degree of clarity whereupon it is delivered to the kettle(21) In lautering production of Apparent Total N-nitroso compounds (ATNC)above the CL of 20 ppb constitute a CCP that should be monitored with chemicaland microbiological analyses Scheduled inspection and under-plate cleaning canprevent insufficient separation of trub from wort (23)
Boiling (CCP5)
Wort is boiled for up to 2 h at atmospheric pressure following the additionof hops (CCP) The shape of copper boiling time and temperature can affect thequality of produced beer The major objectives of wort boiling are a) wort steril-ization and enzyme inactivation b) extraction of bitter and other substances fromhops and formation of flavor compounds and c) evaporation of excess water andwort concentration evaporation of undesirable flavour volatiles Wort contamina-tion of the wort with Enterobacteriaceae from hops can result in various off-flavorsincluding ldquovegetablerdquo and ldquophenolicrdquo taints (24) Correct use of boiler treatmentchemicals steam condensate tasting for carrying over the taints and operation of
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ORDER REPRINTS
12 KOURTIS AND ARVANITOYANNIS
phenol analyses are all essential to avoid chemical contamination and taints devel-opment (23)
Clarification
Wort clarification is conducted either through sedimentation or filtrationWhen whole hop cones are used it is necessary to employ either a hop back ora hop separatorndashfilter The drop in hop usage and the widespread acceptance ofpreisomerized extracts led to utilization of a vertical cylinder known as whirlpoolwhich induces sustainable circulation of the trub collecting as a compact cone in thebase Whirlpools are more suited to larger worts and can also be used with ale Inmodern breweries centrifuges constitute a promising alternative to whirlpools (25)
Cooling
To prepare for fermentation the clear hopped wort is cooled usually in aplate heat exchanger During cooling it is advisable to aerate or even to oxygenatethe wort because next processing step involves yeast growth promoted in the pres-ence of dissolved oxygen despite the low dissolved oxygen concentration in wort(7ndash14 ppm) (22)
Fermentation (CCP6)
Fermentation aims at producing ethanol by fermenting yeasts Yeasts vary intheir behavior during fermentation some strains tend to flocculate trap plug CO2 andrising to the top whereas others do not flocculate and precipitate Several lagers areproduced by bottom fermentation while many types of ales and stouts are producedby top fermentation Saccharomyces cerevisiae is usually the top fermenting yeastin the range of 18ndash22C whilst the bottom-fermenting are strains of Saccharomycesuvarum that function in the range of 7ndash15C (26) Therefore the temperature atwhich fermentation occurs is very crucial for the further stages of beer productionThe modern use of cylindroconical vessels has reduced the fermentation periodfor ales and lagers from 7 to 2 or 3 days and from 10 to 7 days respectively (27)Fermentation is monitored by taking samples for measuring the specific gravityand can be controlled by varying the cooling rate (20) ldquoStuckrdquo fermentation wherethe required ethanol level is not attained and microbial contamination with Lacticacid bacteria mainly Lactobacilii and Pediococcus which cause taints duringmaturation or in bottle storage (28) represent microbiological hazards which arethe only hazard detected at this stage Common causes for ldquostuckrdquo fermentationinclude premature yeast flocculation and yeast failure to metabolize maltotriosedue to repression by glucose (25) A minimum of 90 viable yeast cells (CL) canbe applied to ensure the development of the process During fermentation the pH
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 13
drops from 52 to 42 and by its completion the yeast is removed either as a top orbottom crop and retained to pitch the next fermentation Apart from the conventionalmicrobial detection methods with plate count several rapid detection methodspotentially applied in breweries such as ATP bioluminescence flow cytometryand polymerase chain reaction have been developed to reduce the incubation timefrom 3ndash4 days to 1ndash2 (2930)
Maturation
Maturation includes all those changes occurring between the end of primaryfermentation to beer filtration (31) Ale is matured at relatively warm temperatures12ndash20C while lagers are held under much cooler conditions The warmer temper-atures allow the rapid metabolism of any residual and priming sugars as well asloss of green flavors within 1ndash2 weeks depending on beer type yeast strain wortcomposition and primary fermentation conditions In case of lager the beer used tobe held at refrigerated temperatures for up to several months after fermentation al-lowing formation of proteintannin complexes (18) Today the enzyme addition hassubstantially shortened this process to several weeks during which flavor maturesEnzymes such as papain may be added during transfer between fermentation andmaturation tank The dosage of the proteolytic enzyme varies depending on typeof beer and process Enzyme activity decreases progressively during maturationuntil its inactivation with pasteurization Part of the enzyme absorbed in the yeastsurface is removed during filtration (19)
Filtration (CCP7)
Beer produced during fermentation is turbid and should be clarified prior to itsmarketing This turbidity is due to the presence of yeasts and proteinaceous materi-als associated with carbohydrates and polyphenols The formation of these proteinprecipitates is attributed to cold temperature low pH and poor solubility in alcoholicsolutions (32) To prevent this from occurring in the final product the beer may besubjected to various chill-proofing treatments during its storage These treatmentsgenerally include the addition of clays to absorb the colloidal materials or prote-olytic enzymes used to further solubilize the protein fraction (33) Since oxygenuptake during this process could severely affect the product organoleptic charac-teristics a CCP of dissolved oxygen should be applied with a CL of 02 ppm (34)
Packaging and Sealing
The packing section comprises several CCPs including the containers to beused their cleaning and disinfection (CCP8) the filler line (CCP9) and the sealer(CCP10) The bursting pressure of the bottles as guaranteed by the manufacturerin his specifications for the new glass may no longer be valid in case of reusable
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ORDER REPRINTS
14 KOURTIS AND ARVANITOYANNIS
bottles due to the considerable physical stress during already exerted upon themduring the filling process Insufficient cleaning of reusable bottles due to low temper-atures and concentrations of the employed cleaning solutions as well as presence ofextraneous entrapped materials within bottles and improper emptying consist pos-sible hazards Moreover cleaning solution remnants and shards introduced throughthe procedure pose problems under working conditions The beer filler may be con-taminated by cleaning and disinfection solutions Contamination sources may bedue to inadequate pressure or faulty CIP system resulting in cleaning and disinfect-ing solution remains in the pressure tank or the ring bowl of the filler (3536) Thecrown corker should be correctly installed the filling pressure of bottle caps on themouths of the bottles should be adjusted to ensure a specified blow-off effect toavoid bottle bursting After filling there should be a full bottle inspector detectingglass particles in bottles or possible leakage (37)
Bottle Pasteurization (CCP11)
Pasteurization is carried out to ensure the beer shelf life over a period ofmonths This is accomplished by the development of tunnel pasteurization in whichthe beer bottle is subjected to 60C for 20 min Over-pasteurization which causesoxidation and can adversely affect beer flavor (38) is a potential physical hazardFurthermore it is crucial to check the time-temperature procedure with adequatecorrective actions for assuring the production of a satisfactory product
Bottle Inspection (CCP12)
Bottle inspection after the pasteurization step is important to ensure that bottleshave not been damaged during the process (39) Should such a situation occur theequipment has to be standardized by the production engineer
Labeling and Standardization (CCP13)
Labeling of the package should comply with the requirements of the CodexGeneral for the labeling of prepackaged foods (40) This means that the name of theproduct shall be clearly declared there must be a list of ingredients in descendingorder of proportion no other fruit may be represented pictorially except those usedand ldquothe date of minimum durabilityrdquo will be declared by the month and year inuncoded numerical sequence
BottleCan Packaging (CCP14)
Bottles (cans) are packaged into paperboard boxes of various sizes accordingto the bottle or can dimensions The encountered hazards can be of physical natureconcerning the bottles (cans) condition during the procedure
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 15
Storage (CCP15)
The finished beer undergoes chemical microbiological and organoleptic anal-ysis to ensure that its properties are within its specification range A synoptical pre-sentation of the occurring hazards CCPs CLs and preventive corrective measuresis given in Table 1
SAKE
Introduction
Sake is a fermented liquor made from rice and coming in many varietiesdepending on the raw materials manufacturing process and process after brewing(41) According to the earliest records sake was originally brewed from rice thathad been chewed to reach saccharification followed by natural fermentation Sakebrewed this way was used as a sacred wine in the worship of the Shinto gods Thisassociation with religion Shintoism and Buddhism has caused a deep intertwiningof sake with the traditions and social customs of Japan Thus today sake is servedat ceremonies and celebrations of all kinds (42) Sake has the highest alcoholpercentage by volume of any fermented beverage In its natural undiluted state itmay contain a potent 20 ethanol compared to 3ndash5 for beer or 9ndash12 for winewhich may reach higher values for fortified wines (4344) The central brewersrsquounion divides sake into four basic flavor types on four axes of sweet sour bitterand umai The latter is another translatorrsquos nightmare which generally ends uptranslated as delicious According to position established along these axes sakeis considered to be of ldquomature typerdquo ldquofragrant typerdquo ldquolight and smooth typerdquo orldquofull-bodied typerdquo (Fig 3) However no set of criteria can adequately express themultiplicity of sensations that together create the flavor unique to any individualsake but there is a perceived need for terms which quickly and simply give thegeneral idea
Figure 3 Main flavor types for sake characterization (43)
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ORDER REPRINTS
16 KOURTIS AND ARVANITOYANNIS
Sake Main Production Stages
The main stages for sake production are schematically presented in Figure 4
Raw Materials (CCP1)
The main ingredients of Japanese sake are rice sake rice sake yeastand water The rice most suitable for sake should consist of large grains and shouldbe soft with a white part at its center due to coarse cell structure Rice should complywith the maximum residue limits for pesticides and insecticides established by theCodex Alimentarius Commission for this commodity (45) (CCP chemical hazard)For Japanese sake yellow koji mold (Aspergillus oryzae) is used Sake yeast (Sac-charomyces cerevisiae) is a microbe converting the occurring glucose and mineralsin rice and water into alcohol Employment of bubble-free type yeast eliminates
Figure 4 Process flow diagram of sake production (264647)
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 17
the bubble removal step thus shortening the brewing period and reducing the costShould the factory wish to employ a specific yeast an adequate disinfection ofthe building interior is required otherwise undesirable bacteria may be introducedwhich could prove hazardous to human health (CCP microbiological hazard) (46)
Rice Polishing (CCP2)
The brown rice used for sake production must be first polished to remove theouter portion of the grain which contains fats proteins minerals and amino acidsthat can cause unpleasant flavors leaving the starch residues that are located in thecenter of the grain Nowadays machines are programmed to automatically removewhatever portion of the rice is required for the specific sake (47) The rice polishingratio (73ndash35) is expressed by the following formula (43)
Rice polishing ratio=(weight of white riceweight of brown rice)times100 (1)
The polishing process should be gently carried out because friction results inheat generation thereby greatly affecting water absorption and rice grain structureBroken grains are unlikely to satisfactorily ferment (47) Maybe the most importantstage in sake production consists of yeast starter mash production which can takeplace either with the classical Kimoto or slightly revised Yamahai process or withthe new ldquohigh speedrdquo methods (48)
Washing (CCP3)
After the rice has been polished rice powder clinging to the grain surface isremoved by washing Washing can be carried out either mechanically or manually(laborious hand washing) and should result in removing most of the organic andinorganic impurities reaching the CLs set by Codex Alimentarius of 15 and01 mm respectively
Soaking (Steeping)
Soaking allows rice to absorb the desired amount of water that is crucial toestablishing the rice consistency For sake produced ldquoen masserdquo simply dumpinginto a vat overnight for as long as 14 h is a usual case (47) However high polishedrice may be soaked within minutes In such a case an error of a minute might proveto have dire consequences for the end product (43)
Steaming (CCP4)
Steaming aims at softening the rice grains and breaking down the starchmolecules thus encouraging the growth of Aspergillus oryzae and eliminating all
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18 KOURTIS AND ARVANITOYANNIS
other microorganisms leaving an initially sterile environment prone to sake moldpropagation Presence of lactic acid bacteria (LAB) and yeasts may occur at theend of this step representing a microbiological hazard and resulting in consider-able organoleptic losses The time can vary from 20 to 60 min depending on thebrewer and apparatus employed (40ndash60 and 20 min for traditional and automatedrespectively) (4346)
Cooling
The ensuing division of steamed rice is mainly related to its further use Apart of it is directly cooled by air blower whereas 20ndash30 is transferred to a heatedculture room to be infected with bacteria spores (Aspergillus oryzae) for sake moldproduction
Koji
Since rice grains contain no sugar it is the action of koji mold that converts thestarch in the grains to sugar The steamed rice is first cooled to 15ndash36C before beingtransferred to the koji culture room (30C) Spores of the mold are sprinkled likefine dust on the rice when it has cooled down to 33C After the spores are kneadedinto the steamed rice the rice is heaped and wrapped in cloths to prevent heat andmoisture loss which are two crucial factors for satisfactory bacterial growth Tomaintain uniform temperature and moisture rice is spread and mixed twice the firsttime after 20 hours (upon the appearance of white flecks) and then 7ndash8 h thereafteraccompanied by a distinctive aroma release (48)
Main Mash (Moromi) and Fermentation (CCP5)
In fermentation the occurring chemical hazards are related to heavy metalspresence (As lt 02 Cd lt 001 Pb lt 03 mgL) pesticide residues (as mentionedin Codex Alimentarius) and residues of detergents (absence) and ethylene glycole(absence) Their CLs can be determined and monitored with specific chemicalanalyses The ingredients of main mash (water koji rice and steamed rice) areadded to the starter mash in three steps (moving from small to bigger recipient)over a period of 4 days at successively lower temperatures thus preventing thegrowth of airborne bacteria (Table 2) A day after the addition of all the ingredientsformation of a moist surface showing clear cracks occurs Furthermore the mashbegins to bubble (indication of fermentation progress) as gas is given off during theburgeoning fermentation The fermentation can take place at various temperaturesand its duration depends on it that is at lower temperatures it takes up to twoweeks but the sake aroma is much more appealing compared to that formed athigher temperatures The characteristic sake aroma results from combined flavor
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 19
Table 2 Quantities of Ingredients at Each Stage of Mixing the Main Mash (Moromi)
Yeast 1st 2nd 3rd 4thStarter (Moto) Addition Addition Addition Additiona Total
Total rice (kg) 210 470 850 1470 3000Steamed rice (kg) 140 330 650 1230 2350Koji rice (kg) 70 140 200 240 65030 Brewerrsquos 1200 1200
alcohol (L)Water (L) 230 420 1010 2030 360 405
aTraditional brewers mix the final mash in three stages The fourth addition of alcohol and wateris a controversial postwar development (Kondo 1984)
components of a number of compounds produced during fermentation (49) Theelevated alcohol content of the fermented sake is related to lipid metabolism ofyeast in the presence of proteolipid provided by the koji molds (5051)
Additions (CCP6)
The addition of alcohol at this stage is carried out unless it is clearly statedthat sake does not contain any alcohol from extraneous sources The added alcoholshould not contain methanol or if it does the content of the latter should be lessthan 05 gL because of its toxicity (CCP chemical hazard)
Pressing
Automatic machine presses (consisting of a series of panels with balloon-likesacks attached) are most widely used nowadays instead of the traditional time-consuming method using long bags The remained caked lees are employed forpickle production and cooking or sedimentation of rice particles may occur Alter-natively sedimentation of rice particles at the bottom of the tank may take place
Filtration
Coloring and aging (maturation) inhibition can be effected by using activatedcharcoal filters
Pasteurization (CCP7 and CCP8)
Heating sake preferably twice at 65C kills off the remaining yeast stops en-zyme action and deactivates the lactic acid bacteria that will eventually spoil sakeThis process represents a microbiological hazard for which the specific plant may
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20 KOURTIS AND ARVANITOYANNIS
set CLs However in recent years refrigerated storage and transport have madeunpasteurized sake with characteristic aroma available to the consumer (43)
Dilution
The produced sake in its raw state (Genchu) contains more than 20 alcoholby volume but it is generally diluted to about 15ndash16 vol-
BottlingStorageDistribution
The applied procedures are similar to those mentioned for the beer productionA summary of the occurring hazards CCPs CLs and preventive and correc-
tive measures is given in Table 3
WINE
Introduction
Wines are made from the fruit of Vitis vinifera of which there are a greatnumber of varieties growing in many parts of the world The history of wine isinextricably interwoven with human history It might be as true to say that it waswith wine that civilization began for the vine takes longer to mature than any othercrop and does not produce grapes for wine making until its fourth year It is notexactly known when men first had wine but it was accepted as a gift from the godsthe Egyptians attributed it to Osiris and the Greeks to Dionysos Mesopotamia andthe Caucasian slopes were no doubt early sources of wine from where it was spreadto Egypt and Greece and then to the rest of the world (52)
Wine Main Production Stages
The main stages for wine production are schematically presented in Figure 5
Harvesting (CCP1)
Grape harvesting is a CCP comprising both physical and chemical hazardsPhysically the grapes should be sound without rotten parts otherwise oxidativeand microbial contamination can rapidly develop Therefore harvesting shouldbe conducted with the greatest possible care and an efficient disease managementsystem should be applied (5354) Pesticides play an important role in pest man-agement but they should be handled with care because they constitute chemicalhazards (55) At the time of harvest the grapes must have also reached the correctmaturity when Brix and Total Acidity (TA) levels indicate maturity of wine Sincepesticide and fungicide residues on the surface of the berries constitute chemical
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 21
hazards Oliva et al (56) proposed a rapid and simple gas chromatographic methodfor their determination The maximum residue limits for pesticides in grapes andwines are provided by Codex Alimentarius (45) and Organisation International duVin (57) Finally the bulk bins used for grapes transportation should be effectivelydecontaminated to avoid any microbial infection
Stemming
Stemming includes the removal of stem leaves and grape stalks before crush-ing This procedure has several advantages because the total volume of processedproduct drops by 30 thus resulting in smaller tanks and eventually increasingthe productrsquos alcoholic content (58) However the end of fermentation and the al-cohol content of finished product depend mostly on the Brix level of initial grapesStemmers usually contain a perforated cylinder allowing berries to pass throughbut prevent the passage of stems stalks and leaves
Crushing
Crushing typically immediately follows stemming since some crushing ofthe fruit occurs during stemming The released juice is highly susceptible to oxida-tive browning and microbial contamination The most common crushing processesinvolve pressing the fruit against a perforated wall or passing the fruit through a setof rollers It is very important to avoid crushing the seeds to preclude contaminat-ing the must with seed oils the oxidation of which could produce rancid odors andconstitute an undesirable source of bitter tannins Equally important is the properhandling of product because inappropriate timing might lead to a sudden startof alcoholic fermentation and consequently to higher fermentation temperatureswhile a delay might cause microbial contamination and oxidative browning (59)
Maceration
Maceration is the breakdown of grape solids after crushing of grapes Whilemaceration is always involved in the initial stage of red wine fermentation the long-standing trend has been to limit maceration in white wine production Temperatureand duration of maceration depend on grape and wine variety Usually for white androse wines the maceration time is less than 24 h red destined for early consumptionis macerated for 3ndash5 days and red for aging is macerated from 5 days to 3 weeksFermentation usually occurs during this or at the end of maceration The amount ofthe antimicrobial to be used usually added to white musts that are most sensitive tooxidation depends on the crop health and maceration temperature Sulfur dioxidehas a distinct advantage over other antimicrobial agents because of the relativeinsensitivity of the wine yeasts to its action However it is also toxic or inhibitoryto most bacteria and yeasts (ie Candida Pichia Hansenula) at low concentrations(60) and has a rather low retention capability after the clarification step (61)
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22 KOURTIS AND ARVANITOYANNISTa
ble
3Su
mm
ary
ofH
azar
dsC
CPs
CL
sM
onito
ring
Cor
rect
ive
Act
ions
and
Pers
onne
lRes
pons
ible
for
Sake
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
a(M
CP
)bM
easu
res
CC
PPa
ram
eter
(CL
s)Pr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
CC
ertifi
edsu
pplie
rs
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
wat
er
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Cer
tified
supp
liers
Hea
vym
etal
spr
esen
cein
wat
er
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Eva
luat
ion
ofth
ede
cont
amin
atin
gm
etho
ds
MC
ertifi
edsu
pplie
rs
prop
erpr
epar
atio
n
Mic
robi
alco
ntam
inat
ion
ofth
ecu
lture
100
clea
nM
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Wat
erm
icro
biol
ogic
alqu
ality
Abs
ence
ofpa
thog
ens
Insp
ectio
nof
the
equi
pmen
t
Ric
epo
lishi
ng(C
CP2
)C
Cer
tified
supp
lier
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
polis
hed
rice
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Was
hing
(CC
P3)
PC
ertifi
edsu
pplie
rs
inst
alla
tion
ofau
tom
atic
sepa
rato
r
Ani
mal
impu
ritie
sO
ther
orga
nic
and
inor
gani
cm
ater
01
mm
15
mm
01
mm
Spec
ific
exam
inat
ion
Rew
ashi
ngof
spec
ific
batc
hch
ange
supp
lier
Qua
lity
cont
rol
man
ager
Stea
min
g(f
orun
past
euri
sed
sake
)(C
CP4
)
MG
MP
sche
dule
dm
icro
biol
ogic
alco
ntro
ls
Pres
ence
ofye
asts
and
LA
B
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Spec
ific
batc
hre
proc
essi
ng
CIP
stan
dar-
disa
tion
Qua
lity
cont
rol
man
ager
T
rain
ned
pers
onne
l
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 23
Ferm
enta
tion
(CC
P5)
CM
ater
ialc
ontr
ol
GM
Pco
rros
ion
chec
ks
Hea
vym
etal
pres
ence
Pest
icid
ere
sidu
es
Aslt
02
Cd
lt
001
Pb
lt
03
(mg
L)
Spec
ific
chem
ical
anal
ysis
Dem
etal
lisat
ion
Cha
nge
supp
lier
Rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
GM
Pus
eof
nont
oxic
glyc
ole
Res
idue
sof
ehty
lene
glyc
ole
ampde
terg
ents
0Sp
ecifi
cch
emic
alan
alys
isD
ilutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Alc
ohol
addi
tion
(CC
P6)
CC
ertifi
edsu
pplie
rM
etha
nolc
onte
ntlt
05
gL
GC
exam
inat
ion
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erPa
steu
riza
tion
(CC
P7amp
CC
P8)
MR
unni
ngof
past
euri
ser
acco
rdin
gto
prog
ram
Det
ectio
nof
yeas
tsL
AB
en
zym
atic
activ
ity
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Tem
pera
ture
adju
stm
ent
batc
hre
proc
essi
ng
prop
erm
achi
nery
disi
nfec
tion
Qua
lity
cont
rol
man
ager
Tech
nica
lm
anag
er
aR
egar
ding
the
proc
edur
esof
bottl
ing
stor
age
and
dist
ribu
tion
the
CC
Psar
esi
mila
rto
thos
em
entio
ned
inTa
ble
1fo
rbe
erpr
oduc
tion
bM
CP
stan
dfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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ORDER REPRINTS
28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
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yman
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irel
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itesi
] at
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
nloa
ded
by [
Sule
yman
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irel
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vers
itesi
] at
09
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ber
2011
ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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yman
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irel
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itesi
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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yman
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irel
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itesi
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
Dow
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irel
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itesi
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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ORDER REPRINTS
8 KOURTIS AND ARVANITOYANNIS
Tabl
e1
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Mon
itori
ngC
orre
ctiv
eR
espo
nsib
lePr
oces
sSt
ep(P
MC
)aM
easu
res
CC
PPa
ram
eter
Cri
tical
Lim
itPr
oced
ures
Act
ions
Pers
onne
l
Ferm
enta
tion
(CC
P6)
MIn
spec
tion
ofC
IPsy
stem
and
equi
pmen
t
Lac
toba
cill
iac
etic
acid
bact
eria
and
wil
dye
asts
Pres
ence
in1
mL
plat
e+1
mL
actid
ione
Plat
eco
unt
met
hod
ora
rapi
dde
tect
ion
met
hod
Prop
erdi
sinf
ectio
nof
equi
pmen
tre
proc
essi
ngof
the
batc
h
Qua
lity
cont
rol
man
ager
Filtr
atio
n(C
CP7
)C
Use
CO
2
prefi
lling
offil
ter
with
wat
er
O2
upta
kegt
02
ppm
diss
olve
dO
2
Mea
sure
men
tof
diss
olve
dO
2
Surv
eyof
filtr
atio
nfo
rin
crea
sed
O2
pick
up
Qua
lity
cont
rol
man
ager
Bot
tlec
anin
spec
tor
(CC
P8)
CG
MP
Cle
anin
gpe
rfor
man
ceN
oso
lids
noliq
uid
rem
nant
sE
labo
rate
elec
tron
icre
cogn
ition
syst
ems
afte
rC
IP
Rew
ashi
ngof
bottl
esC
IPsy
stem
insp
ectio
n
Qua
lity
cont
rol
man
ager
PC
ertifi
edsu
pplie
rpr
oper
hand
ling
ofbo
ttles
Bot
tles
prop
erfo
rfo
ods
and
drin
ks
bottl
esco
nditi
on
Cra
cks
scra
tche
sab
senc
eO
n-lin
evi
sual
cont
rol
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlec
anfil
ler
(CC
P9)
CIn
stal
latio
nof
cont
rolli
ngeq
uipm
ento
nth
eC
IPsy
stem
Con
tam
inat
ion
with
dete
rgen
tsC
ompl
ete
abse
nce
Org
anol
eptic
exam
inat
ion
offil
led
bottl
es
Bat
chre
ject
ion
Tra
ined
pers
onne
l
Bot
tlec
anse
aler
(CC
P10)
PC
orre
ctin
stal
latio
nof
equi
pmen
tB
low
-off
effe
ctO
ccur
renc
ere
duce
dto
anac
cept
able
leve
l
Con
trol
sets
ealin
gpr
essu
reA
utom
atic
rem
oval
ofde
stro
yed
bottl
es
Tra
ined
pers
onne
l
Bot
tlec
anpa
steu
riza
tion
(CC
P11)
PR
unni
ngpa
steu
rise
rac
cord
ing
topr
ogra
m
Oxi
datio
nca
used
ofw
rong
tem
pera
ture
-tim
ese
t
Max
65 C
for
20m
inq
uick
cool
ing
atth
eex
it
Con
tinuo
uson
-lin
etim
e-te
mpe
ratu
rech
ecki
ng
Adj
ust
tem
pera
ture
m
aint
ain
equi
pmen
t
Tech
nica
lm
anag
er
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nloa
ded
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irel
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] at
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ber
2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 9
Bot
tlec
anin
spec
tion
(CC
P12)
PR
egul
arin
spec
tion
ofth
em
achi
nery
Phys
ical
dam
age
Occ
urre
nce
redu
ced
toan
acce
ptab
lele
vel
On-
line
mon
itori
ngE
quip
men
tst
anda
rdis
atio
nTe
chni
cal
man
ager
Lab
elin
g(C
CP1
3)P
Car
eful
sele
ctio
nof
the
etiq
uette
sM
ispl
aced
etiq
uette
sR
educ
edto
anac
cept
able
leve
lV
isua
lche
cks
cont
rolo
fth
eeq
uipm
ent
Rel
abel
ing
the
spec
ific
batc
hT
rain
edpe
rson
nel
Bot
tlec
anpa
ckag
ing
(CC
P14)
PC
orre
ctin
stal
latio
nof
the
equi
pmen
tB
ottle
sco
nditi
ondu
ring
palle
tisat
ion
Abs
ence
ofri
fts
inth
elu
tec
rack
orsc
ratc
hes
On-
line
visu
alco
ntro
lA
djus
tthe
equi
pmen
tpa
ram
eter
s(s
peed
pre
ssur
e)
Tech
nica
lm
anag
er
Stor
age
(CC
P15)
PC
ontr
olst
orag
eco
nditi
ons
Org
anol
eptic
cond
ition
ofbe
erSp
ecifi
edby
the
part
icul
arpl
ant
Sche
dule
dco
ntro
lsof
finis
hed
prod
uct
Adj
ustt
hest
oreh
ouse
cond
ition
s
Tra
ined
pers
onne
l
aP
MC
stan
dfo
rph
ysic
alm
icro
biol
ogic
alan
dch
emic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
10 KOURTIS AND ARVANITOYANNIS
than malt are sometimes used as an additional source of extract to supplementmalt Unmalted cereal adjuncts usually contain no active enzymes and thereforerely on malt or exogenous enzymes to provide the necessary enzymes for starchconversion (19)
Yeast growth cannot be separated from the fermentation process and it isnecessary to the production of both beer and fresh yeast for use in subsequentfermentations The quality control of yeasts comprises a) the selection maintenanceand supply of a suitable strain and b) the routine assessment of purity and detectionof microbial contamination (CCP) (20)
Malting (CCP2)
This process involves steeping the barley in a shallow bed of water at a tem-perature of 10ndash15C so that its moisture content amounts to 45 wt- of barleyBarley is then allowed to germinate under controlled temperature conditions atapproximately 15C and RH100 with constant turning to prevent matting therootlets The barleycorn undergoes germination through air passage via the germi-nating malt for 3ndash5 days Gentle heating stops germination due to moisture removaland promotes formation of flavor compounds The kiln temperature regime is cru-cial for the color of malt and the survival of enzymes to be used in the mashingprocess Kilning duration usually varies between 24 and 48 h Time temperatureand moisture content are varied to control color and flavor development Chemicalmicrobiological and physical hazards may be encountered in this step In partic-ular nitrosodimethylamine (NDMA) production during kilning (reaction of NOx
with organic materials) constitutes a chemical hazard with a critical limit (CL) at25 ppb because of its suspected carcinogenic effect In addition mycotoxin pro-duction more than 0004 mgL and color and flavor alteration represent chemicaland physical hazards respectively The NDMA content in malt can be controlled byusing indirect heating systems or by carefully maintained and controlled low-NOx
burners Regular checks should nevertheless be carried out by the maltster so thatthe residual risk caused by polluted air is kept as low as possible (17) The finishedmalt has its rootlets removed and is screened to produce the uniform quality Duringthe malting process two important changes occur a) the barley develops its ownenzyme systems and b) the naturally produced enzymes start to break down the cellstructure of the endosperm (19) Malt quality control tests include hot water extractcolor soluble nitrogen total nitrogen moisture enzyme activities viscosity andlautering prediction tests The microbiological status of malt used in the followingsteps (CCP) is very much dependent on its handling operations after production (16)
Milling
The main function of dry or wet milling is to reduce the malt particle sizeto form grist (ground or milled grain) The particle size reduction facilitates the
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 11
extraction of soluble components mainly sugars and nitrogenous compounds fromthe endosperm (21)
Mashing (CCP3)
Mashing the first step in wort production involves extracting soluble materi-als from the milled malt This is accomplished by feeding the grist through Steelrsquosmasher a hydrator consisting of a large-bore tube bent at right angles During itspassage through the vertical portion of tube the grist is spayed with hot water (typ-ically 65C) and then mixed with the help of a revolving screw (22) The floatingendosperm particles hydrate and undergo further amylolytic scission by α- andβ-amylases Processors adjust the pH and temperature conditions to allow bothenzymes with a range of susceptibility to pH and temperature to work effectivelyNDMA production (CL = 25 ppb) as well as possible detergent residues constitutepotential chemical hazards for public health Continuous monitoring at the process-ing and adjustment of the lautering program and Cleaning In Place (CIP) systemwhen deviation occurs are proper preventive and corrective actions respectively
Lautering (CCP4)
The lauter tun is a vessel normally rinsed thoroughly with a sparging or hotwater delivery system before receiving the mash which precipitates at the flat floorof slotted stainless steel or brass plates At tun center there is a lautering machineon the shaft of which rotating rakes are attached to facilitate draining the wortinto a collection vessel called grant The wort is recirculated through the lauter tununtil it reaches a certain degree of clarity whereupon it is delivered to the kettle(21) In lautering production of Apparent Total N-nitroso compounds (ATNC)above the CL of 20 ppb constitute a CCP that should be monitored with chemicaland microbiological analyses Scheduled inspection and under-plate cleaning canprevent insufficient separation of trub from wort (23)
Boiling (CCP5)
Wort is boiled for up to 2 h at atmospheric pressure following the additionof hops (CCP) The shape of copper boiling time and temperature can affect thequality of produced beer The major objectives of wort boiling are a) wort steril-ization and enzyme inactivation b) extraction of bitter and other substances fromhops and formation of flavor compounds and c) evaporation of excess water andwort concentration evaporation of undesirable flavour volatiles Wort contamina-tion of the wort with Enterobacteriaceae from hops can result in various off-flavorsincluding ldquovegetablerdquo and ldquophenolicrdquo taints (24) Correct use of boiler treatmentchemicals steam condensate tasting for carrying over the taints and operation of
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ORDER REPRINTS
12 KOURTIS AND ARVANITOYANNIS
phenol analyses are all essential to avoid chemical contamination and taints devel-opment (23)
Clarification
Wort clarification is conducted either through sedimentation or filtrationWhen whole hop cones are used it is necessary to employ either a hop back ora hop separatorndashfilter The drop in hop usage and the widespread acceptance ofpreisomerized extracts led to utilization of a vertical cylinder known as whirlpoolwhich induces sustainable circulation of the trub collecting as a compact cone in thebase Whirlpools are more suited to larger worts and can also be used with ale Inmodern breweries centrifuges constitute a promising alternative to whirlpools (25)
Cooling
To prepare for fermentation the clear hopped wort is cooled usually in aplate heat exchanger During cooling it is advisable to aerate or even to oxygenatethe wort because next processing step involves yeast growth promoted in the pres-ence of dissolved oxygen despite the low dissolved oxygen concentration in wort(7ndash14 ppm) (22)
Fermentation (CCP6)
Fermentation aims at producing ethanol by fermenting yeasts Yeasts vary intheir behavior during fermentation some strains tend to flocculate trap plug CO2 andrising to the top whereas others do not flocculate and precipitate Several lagers areproduced by bottom fermentation while many types of ales and stouts are producedby top fermentation Saccharomyces cerevisiae is usually the top fermenting yeastin the range of 18ndash22C whilst the bottom-fermenting are strains of Saccharomycesuvarum that function in the range of 7ndash15C (26) Therefore the temperature atwhich fermentation occurs is very crucial for the further stages of beer productionThe modern use of cylindroconical vessels has reduced the fermentation periodfor ales and lagers from 7 to 2 or 3 days and from 10 to 7 days respectively (27)Fermentation is monitored by taking samples for measuring the specific gravityand can be controlled by varying the cooling rate (20) ldquoStuckrdquo fermentation wherethe required ethanol level is not attained and microbial contamination with Lacticacid bacteria mainly Lactobacilii and Pediococcus which cause taints duringmaturation or in bottle storage (28) represent microbiological hazards which arethe only hazard detected at this stage Common causes for ldquostuckrdquo fermentationinclude premature yeast flocculation and yeast failure to metabolize maltotriosedue to repression by glucose (25) A minimum of 90 viable yeast cells (CL) canbe applied to ensure the development of the process During fermentation the pH
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 13
drops from 52 to 42 and by its completion the yeast is removed either as a top orbottom crop and retained to pitch the next fermentation Apart from the conventionalmicrobial detection methods with plate count several rapid detection methodspotentially applied in breweries such as ATP bioluminescence flow cytometryand polymerase chain reaction have been developed to reduce the incubation timefrom 3ndash4 days to 1ndash2 (2930)
Maturation
Maturation includes all those changes occurring between the end of primaryfermentation to beer filtration (31) Ale is matured at relatively warm temperatures12ndash20C while lagers are held under much cooler conditions The warmer temper-atures allow the rapid metabolism of any residual and priming sugars as well asloss of green flavors within 1ndash2 weeks depending on beer type yeast strain wortcomposition and primary fermentation conditions In case of lager the beer used tobe held at refrigerated temperatures for up to several months after fermentation al-lowing formation of proteintannin complexes (18) Today the enzyme addition hassubstantially shortened this process to several weeks during which flavor maturesEnzymes such as papain may be added during transfer between fermentation andmaturation tank The dosage of the proteolytic enzyme varies depending on typeof beer and process Enzyme activity decreases progressively during maturationuntil its inactivation with pasteurization Part of the enzyme absorbed in the yeastsurface is removed during filtration (19)
Filtration (CCP7)
Beer produced during fermentation is turbid and should be clarified prior to itsmarketing This turbidity is due to the presence of yeasts and proteinaceous materi-als associated with carbohydrates and polyphenols The formation of these proteinprecipitates is attributed to cold temperature low pH and poor solubility in alcoholicsolutions (32) To prevent this from occurring in the final product the beer may besubjected to various chill-proofing treatments during its storage These treatmentsgenerally include the addition of clays to absorb the colloidal materials or prote-olytic enzymes used to further solubilize the protein fraction (33) Since oxygenuptake during this process could severely affect the product organoleptic charac-teristics a CCP of dissolved oxygen should be applied with a CL of 02 ppm (34)
Packaging and Sealing
The packing section comprises several CCPs including the containers to beused their cleaning and disinfection (CCP8) the filler line (CCP9) and the sealer(CCP10) The bursting pressure of the bottles as guaranteed by the manufacturerin his specifications for the new glass may no longer be valid in case of reusable
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ORDER REPRINTS
14 KOURTIS AND ARVANITOYANNIS
bottles due to the considerable physical stress during already exerted upon themduring the filling process Insufficient cleaning of reusable bottles due to low temper-atures and concentrations of the employed cleaning solutions as well as presence ofextraneous entrapped materials within bottles and improper emptying consist pos-sible hazards Moreover cleaning solution remnants and shards introduced throughthe procedure pose problems under working conditions The beer filler may be con-taminated by cleaning and disinfection solutions Contamination sources may bedue to inadequate pressure or faulty CIP system resulting in cleaning and disinfect-ing solution remains in the pressure tank or the ring bowl of the filler (3536) Thecrown corker should be correctly installed the filling pressure of bottle caps on themouths of the bottles should be adjusted to ensure a specified blow-off effect toavoid bottle bursting After filling there should be a full bottle inspector detectingglass particles in bottles or possible leakage (37)
Bottle Pasteurization (CCP11)
Pasteurization is carried out to ensure the beer shelf life over a period ofmonths This is accomplished by the development of tunnel pasteurization in whichthe beer bottle is subjected to 60C for 20 min Over-pasteurization which causesoxidation and can adversely affect beer flavor (38) is a potential physical hazardFurthermore it is crucial to check the time-temperature procedure with adequatecorrective actions for assuring the production of a satisfactory product
Bottle Inspection (CCP12)
Bottle inspection after the pasteurization step is important to ensure that bottleshave not been damaged during the process (39) Should such a situation occur theequipment has to be standardized by the production engineer
Labeling and Standardization (CCP13)
Labeling of the package should comply with the requirements of the CodexGeneral for the labeling of prepackaged foods (40) This means that the name of theproduct shall be clearly declared there must be a list of ingredients in descendingorder of proportion no other fruit may be represented pictorially except those usedand ldquothe date of minimum durabilityrdquo will be declared by the month and year inuncoded numerical sequence
BottleCan Packaging (CCP14)
Bottles (cans) are packaged into paperboard boxes of various sizes accordingto the bottle or can dimensions The encountered hazards can be of physical natureconcerning the bottles (cans) condition during the procedure
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 15
Storage (CCP15)
The finished beer undergoes chemical microbiological and organoleptic anal-ysis to ensure that its properties are within its specification range A synoptical pre-sentation of the occurring hazards CCPs CLs and preventive corrective measuresis given in Table 1
SAKE
Introduction
Sake is a fermented liquor made from rice and coming in many varietiesdepending on the raw materials manufacturing process and process after brewing(41) According to the earliest records sake was originally brewed from rice thathad been chewed to reach saccharification followed by natural fermentation Sakebrewed this way was used as a sacred wine in the worship of the Shinto gods Thisassociation with religion Shintoism and Buddhism has caused a deep intertwiningof sake with the traditions and social customs of Japan Thus today sake is servedat ceremonies and celebrations of all kinds (42) Sake has the highest alcoholpercentage by volume of any fermented beverage In its natural undiluted state itmay contain a potent 20 ethanol compared to 3ndash5 for beer or 9ndash12 for winewhich may reach higher values for fortified wines (4344) The central brewersrsquounion divides sake into four basic flavor types on four axes of sweet sour bitterand umai The latter is another translatorrsquos nightmare which generally ends uptranslated as delicious According to position established along these axes sakeis considered to be of ldquomature typerdquo ldquofragrant typerdquo ldquolight and smooth typerdquo orldquofull-bodied typerdquo (Fig 3) However no set of criteria can adequately express themultiplicity of sensations that together create the flavor unique to any individualsake but there is a perceived need for terms which quickly and simply give thegeneral idea
Figure 3 Main flavor types for sake characterization (43)
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ORDER REPRINTS
16 KOURTIS AND ARVANITOYANNIS
Sake Main Production Stages
The main stages for sake production are schematically presented in Figure 4
Raw Materials (CCP1)
The main ingredients of Japanese sake are rice sake rice sake yeastand water The rice most suitable for sake should consist of large grains and shouldbe soft with a white part at its center due to coarse cell structure Rice should complywith the maximum residue limits for pesticides and insecticides established by theCodex Alimentarius Commission for this commodity (45) (CCP chemical hazard)For Japanese sake yellow koji mold (Aspergillus oryzae) is used Sake yeast (Sac-charomyces cerevisiae) is a microbe converting the occurring glucose and mineralsin rice and water into alcohol Employment of bubble-free type yeast eliminates
Figure 4 Process flow diagram of sake production (264647)
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 17
the bubble removal step thus shortening the brewing period and reducing the costShould the factory wish to employ a specific yeast an adequate disinfection ofthe building interior is required otherwise undesirable bacteria may be introducedwhich could prove hazardous to human health (CCP microbiological hazard) (46)
Rice Polishing (CCP2)
The brown rice used for sake production must be first polished to remove theouter portion of the grain which contains fats proteins minerals and amino acidsthat can cause unpleasant flavors leaving the starch residues that are located in thecenter of the grain Nowadays machines are programmed to automatically removewhatever portion of the rice is required for the specific sake (47) The rice polishingratio (73ndash35) is expressed by the following formula (43)
Rice polishing ratio=(weight of white riceweight of brown rice)times100 (1)
The polishing process should be gently carried out because friction results inheat generation thereby greatly affecting water absorption and rice grain structureBroken grains are unlikely to satisfactorily ferment (47) Maybe the most importantstage in sake production consists of yeast starter mash production which can takeplace either with the classical Kimoto or slightly revised Yamahai process or withthe new ldquohigh speedrdquo methods (48)
Washing (CCP3)
After the rice has been polished rice powder clinging to the grain surface isremoved by washing Washing can be carried out either mechanically or manually(laborious hand washing) and should result in removing most of the organic andinorganic impurities reaching the CLs set by Codex Alimentarius of 15 and01 mm respectively
Soaking (Steeping)
Soaking allows rice to absorb the desired amount of water that is crucial toestablishing the rice consistency For sake produced ldquoen masserdquo simply dumpinginto a vat overnight for as long as 14 h is a usual case (47) However high polishedrice may be soaked within minutes In such a case an error of a minute might proveto have dire consequences for the end product (43)
Steaming (CCP4)
Steaming aims at softening the rice grains and breaking down the starchmolecules thus encouraging the growth of Aspergillus oryzae and eliminating all
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ORDER REPRINTS
18 KOURTIS AND ARVANITOYANNIS
other microorganisms leaving an initially sterile environment prone to sake moldpropagation Presence of lactic acid bacteria (LAB) and yeasts may occur at theend of this step representing a microbiological hazard and resulting in consider-able organoleptic losses The time can vary from 20 to 60 min depending on thebrewer and apparatus employed (40ndash60 and 20 min for traditional and automatedrespectively) (4346)
Cooling
The ensuing division of steamed rice is mainly related to its further use Apart of it is directly cooled by air blower whereas 20ndash30 is transferred to a heatedculture room to be infected with bacteria spores (Aspergillus oryzae) for sake moldproduction
Koji
Since rice grains contain no sugar it is the action of koji mold that converts thestarch in the grains to sugar The steamed rice is first cooled to 15ndash36C before beingtransferred to the koji culture room (30C) Spores of the mold are sprinkled likefine dust on the rice when it has cooled down to 33C After the spores are kneadedinto the steamed rice the rice is heaped and wrapped in cloths to prevent heat andmoisture loss which are two crucial factors for satisfactory bacterial growth Tomaintain uniform temperature and moisture rice is spread and mixed twice the firsttime after 20 hours (upon the appearance of white flecks) and then 7ndash8 h thereafteraccompanied by a distinctive aroma release (48)
Main Mash (Moromi) and Fermentation (CCP5)
In fermentation the occurring chemical hazards are related to heavy metalspresence (As lt 02 Cd lt 001 Pb lt 03 mgL) pesticide residues (as mentionedin Codex Alimentarius) and residues of detergents (absence) and ethylene glycole(absence) Their CLs can be determined and monitored with specific chemicalanalyses The ingredients of main mash (water koji rice and steamed rice) areadded to the starter mash in three steps (moving from small to bigger recipient)over a period of 4 days at successively lower temperatures thus preventing thegrowth of airborne bacteria (Table 2) A day after the addition of all the ingredientsformation of a moist surface showing clear cracks occurs Furthermore the mashbegins to bubble (indication of fermentation progress) as gas is given off during theburgeoning fermentation The fermentation can take place at various temperaturesand its duration depends on it that is at lower temperatures it takes up to twoweeks but the sake aroma is much more appealing compared to that formed athigher temperatures The characteristic sake aroma results from combined flavor
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 19
Table 2 Quantities of Ingredients at Each Stage of Mixing the Main Mash (Moromi)
Yeast 1st 2nd 3rd 4thStarter (Moto) Addition Addition Addition Additiona Total
Total rice (kg) 210 470 850 1470 3000Steamed rice (kg) 140 330 650 1230 2350Koji rice (kg) 70 140 200 240 65030 Brewerrsquos 1200 1200
alcohol (L)Water (L) 230 420 1010 2030 360 405
aTraditional brewers mix the final mash in three stages The fourth addition of alcohol and wateris a controversial postwar development (Kondo 1984)
components of a number of compounds produced during fermentation (49) Theelevated alcohol content of the fermented sake is related to lipid metabolism ofyeast in the presence of proteolipid provided by the koji molds (5051)
Additions (CCP6)
The addition of alcohol at this stage is carried out unless it is clearly statedthat sake does not contain any alcohol from extraneous sources The added alcoholshould not contain methanol or if it does the content of the latter should be lessthan 05 gL because of its toxicity (CCP chemical hazard)
Pressing
Automatic machine presses (consisting of a series of panels with balloon-likesacks attached) are most widely used nowadays instead of the traditional time-consuming method using long bags The remained caked lees are employed forpickle production and cooking or sedimentation of rice particles may occur Alter-natively sedimentation of rice particles at the bottom of the tank may take place
Filtration
Coloring and aging (maturation) inhibition can be effected by using activatedcharcoal filters
Pasteurization (CCP7 and CCP8)
Heating sake preferably twice at 65C kills off the remaining yeast stops en-zyme action and deactivates the lactic acid bacteria that will eventually spoil sakeThis process represents a microbiological hazard for which the specific plant may
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ORDER REPRINTS
20 KOURTIS AND ARVANITOYANNIS
set CLs However in recent years refrigerated storage and transport have madeunpasteurized sake with characteristic aroma available to the consumer (43)
Dilution
The produced sake in its raw state (Genchu) contains more than 20 alcoholby volume but it is generally diluted to about 15ndash16 vol-
BottlingStorageDistribution
The applied procedures are similar to those mentioned for the beer productionA summary of the occurring hazards CCPs CLs and preventive and correc-
tive measures is given in Table 3
WINE
Introduction
Wines are made from the fruit of Vitis vinifera of which there are a greatnumber of varieties growing in many parts of the world The history of wine isinextricably interwoven with human history It might be as true to say that it waswith wine that civilization began for the vine takes longer to mature than any othercrop and does not produce grapes for wine making until its fourth year It is notexactly known when men first had wine but it was accepted as a gift from the godsthe Egyptians attributed it to Osiris and the Greeks to Dionysos Mesopotamia andthe Caucasian slopes were no doubt early sources of wine from where it was spreadto Egypt and Greece and then to the rest of the world (52)
Wine Main Production Stages
The main stages for wine production are schematically presented in Figure 5
Harvesting (CCP1)
Grape harvesting is a CCP comprising both physical and chemical hazardsPhysically the grapes should be sound without rotten parts otherwise oxidativeand microbial contamination can rapidly develop Therefore harvesting shouldbe conducted with the greatest possible care and an efficient disease managementsystem should be applied (5354) Pesticides play an important role in pest man-agement but they should be handled with care because they constitute chemicalhazards (55) At the time of harvest the grapes must have also reached the correctmaturity when Brix and Total Acidity (TA) levels indicate maturity of wine Sincepesticide and fungicide residues on the surface of the berries constitute chemical
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 21
hazards Oliva et al (56) proposed a rapid and simple gas chromatographic methodfor their determination The maximum residue limits for pesticides in grapes andwines are provided by Codex Alimentarius (45) and Organisation International duVin (57) Finally the bulk bins used for grapes transportation should be effectivelydecontaminated to avoid any microbial infection
Stemming
Stemming includes the removal of stem leaves and grape stalks before crush-ing This procedure has several advantages because the total volume of processedproduct drops by 30 thus resulting in smaller tanks and eventually increasingthe productrsquos alcoholic content (58) However the end of fermentation and the al-cohol content of finished product depend mostly on the Brix level of initial grapesStemmers usually contain a perforated cylinder allowing berries to pass throughbut prevent the passage of stems stalks and leaves
Crushing
Crushing typically immediately follows stemming since some crushing ofthe fruit occurs during stemming The released juice is highly susceptible to oxida-tive browning and microbial contamination The most common crushing processesinvolve pressing the fruit against a perforated wall or passing the fruit through a setof rollers It is very important to avoid crushing the seeds to preclude contaminat-ing the must with seed oils the oxidation of which could produce rancid odors andconstitute an undesirable source of bitter tannins Equally important is the properhandling of product because inappropriate timing might lead to a sudden startof alcoholic fermentation and consequently to higher fermentation temperatureswhile a delay might cause microbial contamination and oxidative browning (59)
Maceration
Maceration is the breakdown of grape solids after crushing of grapes Whilemaceration is always involved in the initial stage of red wine fermentation the long-standing trend has been to limit maceration in white wine production Temperatureand duration of maceration depend on grape and wine variety Usually for white androse wines the maceration time is less than 24 h red destined for early consumptionis macerated for 3ndash5 days and red for aging is macerated from 5 days to 3 weeksFermentation usually occurs during this or at the end of maceration The amount ofthe antimicrobial to be used usually added to white musts that are most sensitive tooxidation depends on the crop health and maceration temperature Sulfur dioxidehas a distinct advantage over other antimicrobial agents because of the relativeinsensitivity of the wine yeasts to its action However it is also toxic or inhibitoryto most bacteria and yeasts (ie Candida Pichia Hansenula) at low concentrations(60) and has a rather low retention capability after the clarification step (61)
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ORDER REPRINTS
22 KOURTIS AND ARVANITOYANNISTa
ble
3Su
mm
ary
ofH
azar
dsC
CPs
CL
sM
onito
ring
Cor
rect
ive
Act
ions
and
Pers
onne
lRes
pons
ible
for
Sake
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
a(M
CP
)bM
easu
res
CC
PPa
ram
eter
(CL
s)Pr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
CC
ertifi
edsu
pplie
rs
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
wat
er
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Cer
tified
supp
liers
Hea
vym
etal
spr
esen
cein
wat
er
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Eva
luat
ion
ofth
ede
cont
amin
atin
gm
etho
ds
MC
ertifi
edsu
pplie
rs
prop
erpr
epar
atio
n
Mic
robi
alco
ntam
inat
ion
ofth
ecu
lture
100
clea
nM
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Wat
erm
icro
biol
ogic
alqu
ality
Abs
ence
ofpa
thog
ens
Insp
ectio
nof
the
equi
pmen
t
Ric
epo
lishi
ng(C
CP2
)C
Cer
tified
supp
lier
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
polis
hed
rice
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Was
hing
(CC
P3)
PC
ertifi
edsu
pplie
rs
inst
alla
tion
ofau
tom
atic
sepa
rato
r
Ani
mal
impu
ritie
sO
ther
orga
nic
and
inor
gani
cm
ater
01
mm
15
mm
01
mm
Spec
ific
exam
inat
ion
Rew
ashi
ngof
spec
ific
batc
hch
ange
supp
lier
Qua
lity
cont
rol
man
ager
Stea
min
g(f
orun
past
euri
sed
sake
)(C
CP4
)
MG
MP
sche
dule
dm
icro
biol
ogic
alco
ntro
ls
Pres
ence
ofye
asts
and
LA
B
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Spec
ific
batc
hre
proc
essi
ng
CIP
stan
dar-
disa
tion
Qua
lity
cont
rol
man
ager
T
rain
ned
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 23
Ferm
enta
tion
(CC
P5)
CM
ater
ialc
ontr
ol
GM
Pco
rros
ion
chec
ks
Hea
vym
etal
pres
ence
Pest
icid
ere
sidu
es
Aslt
02
Cd
lt
001
Pb
lt
03
(mg
L)
Spec
ific
chem
ical
anal
ysis
Dem
etal
lisat
ion
Cha
nge
supp
lier
Rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
GM
Pus
eof
nont
oxic
glyc
ole
Res
idue
sof
ehty
lene
glyc
ole
ampde
terg
ents
0Sp
ecifi
cch
emic
alan
alys
isD
ilutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Alc
ohol
addi
tion
(CC
P6)
CC
ertifi
edsu
pplie
rM
etha
nolc
onte
ntlt
05
gL
GC
exam
inat
ion
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erPa
steu
riza
tion
(CC
P7amp
CC
P8)
MR
unni
ngof
past
euri
ser
acco
rdin
gto
prog
ram
Det
ectio
nof
yeas
tsL
AB
en
zym
atic
activ
ity
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Tem
pera
ture
adju
stm
ent
batc
hre
proc
essi
ng
prop
erm
achi
nery
disi
nfec
tion
Qua
lity
cont
rol
man
ager
Tech
nica
lm
anag
er
aR
egar
ding
the
proc
edur
esof
bottl
ing
stor
age
and
dist
ribu
tion
the
CC
Psar
esi
mila
rto
thos
em
entio
ned
inTa
ble
1fo
rbe
erpr
oduc
tion
bM
CP
stan
dfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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ORDER REPRINTS
26 KOURTIS AND ARVANITOYANNIS
Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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2011
ORDER REPRINTS
28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
Dow
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
Dow
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
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yman
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irel
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
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ded
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irel
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ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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Order now
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 9
Bot
tlec
anin
spec
tion
(CC
P12)
PR
egul
arin
spec
tion
ofth
em
achi
nery
Phys
ical
dam
age
Occ
urre
nce
redu
ced
toan
acce
ptab
lele
vel
On-
line
mon
itori
ngE
quip
men
tst
anda
rdis
atio
nTe
chni
cal
man
ager
Lab
elin
g(C
CP1
3)P
Car
eful
sele
ctio
nof
the
etiq
uette
sM
ispl
aced
etiq
uette
sR
educ
edto
anac
cept
able
leve
lV
isua
lche
cks
cont
rolo
fth
eeq
uipm
ent
Rel
abel
ing
the
spec
ific
batc
hT
rain
edpe
rson
nel
Bot
tlec
anpa
ckag
ing
(CC
P14)
PC
orre
ctin
stal
latio
nof
the
equi
pmen
tB
ottle
sco
nditi
ondu
ring
palle
tisat
ion
Abs
ence
ofri
fts
inth
elu
tec
rack
orsc
ratc
hes
On-
line
visu
alco
ntro
lA
djus
tthe
equi
pmen
tpa
ram
eter
s(s
peed
pre
ssur
e)
Tech
nica
lm
anag
er
Stor
age
(CC
P15)
PC
ontr
olst
orag
eco
nditi
ons
Org
anol
eptic
cond
ition
ofbe
erSp
ecifi
edby
the
part
icul
arpl
ant
Sche
dule
dco
ntro
lsof
finis
hed
prod
uct
Adj
ustt
hest
oreh
ouse
cond
ition
s
Tra
ined
pers
onne
l
aP
MC
stan
dfo
rph
ysic
alm
icro
biol
ogic
alan
dch
emic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
10 KOURTIS AND ARVANITOYANNIS
than malt are sometimes used as an additional source of extract to supplementmalt Unmalted cereal adjuncts usually contain no active enzymes and thereforerely on malt or exogenous enzymes to provide the necessary enzymes for starchconversion (19)
Yeast growth cannot be separated from the fermentation process and it isnecessary to the production of both beer and fresh yeast for use in subsequentfermentations The quality control of yeasts comprises a) the selection maintenanceand supply of a suitable strain and b) the routine assessment of purity and detectionof microbial contamination (CCP) (20)
Malting (CCP2)
This process involves steeping the barley in a shallow bed of water at a tem-perature of 10ndash15C so that its moisture content amounts to 45 wt- of barleyBarley is then allowed to germinate under controlled temperature conditions atapproximately 15C and RH100 with constant turning to prevent matting therootlets The barleycorn undergoes germination through air passage via the germi-nating malt for 3ndash5 days Gentle heating stops germination due to moisture removaland promotes formation of flavor compounds The kiln temperature regime is cru-cial for the color of malt and the survival of enzymes to be used in the mashingprocess Kilning duration usually varies between 24 and 48 h Time temperatureand moisture content are varied to control color and flavor development Chemicalmicrobiological and physical hazards may be encountered in this step In partic-ular nitrosodimethylamine (NDMA) production during kilning (reaction of NOx
with organic materials) constitutes a chemical hazard with a critical limit (CL) at25 ppb because of its suspected carcinogenic effect In addition mycotoxin pro-duction more than 0004 mgL and color and flavor alteration represent chemicaland physical hazards respectively The NDMA content in malt can be controlled byusing indirect heating systems or by carefully maintained and controlled low-NOx
burners Regular checks should nevertheless be carried out by the maltster so thatthe residual risk caused by polluted air is kept as low as possible (17) The finishedmalt has its rootlets removed and is screened to produce the uniform quality Duringthe malting process two important changes occur a) the barley develops its ownenzyme systems and b) the naturally produced enzymes start to break down the cellstructure of the endosperm (19) Malt quality control tests include hot water extractcolor soluble nitrogen total nitrogen moisture enzyme activities viscosity andlautering prediction tests The microbiological status of malt used in the followingsteps (CCP) is very much dependent on its handling operations after production (16)
Milling
The main function of dry or wet milling is to reduce the malt particle sizeto form grist (ground or milled grain) The particle size reduction facilitates the
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 11
extraction of soluble components mainly sugars and nitrogenous compounds fromthe endosperm (21)
Mashing (CCP3)
Mashing the first step in wort production involves extracting soluble materi-als from the milled malt This is accomplished by feeding the grist through Steelrsquosmasher a hydrator consisting of a large-bore tube bent at right angles During itspassage through the vertical portion of tube the grist is spayed with hot water (typ-ically 65C) and then mixed with the help of a revolving screw (22) The floatingendosperm particles hydrate and undergo further amylolytic scission by α- andβ-amylases Processors adjust the pH and temperature conditions to allow bothenzymes with a range of susceptibility to pH and temperature to work effectivelyNDMA production (CL = 25 ppb) as well as possible detergent residues constitutepotential chemical hazards for public health Continuous monitoring at the process-ing and adjustment of the lautering program and Cleaning In Place (CIP) systemwhen deviation occurs are proper preventive and corrective actions respectively
Lautering (CCP4)
The lauter tun is a vessel normally rinsed thoroughly with a sparging or hotwater delivery system before receiving the mash which precipitates at the flat floorof slotted stainless steel or brass plates At tun center there is a lautering machineon the shaft of which rotating rakes are attached to facilitate draining the wortinto a collection vessel called grant The wort is recirculated through the lauter tununtil it reaches a certain degree of clarity whereupon it is delivered to the kettle(21) In lautering production of Apparent Total N-nitroso compounds (ATNC)above the CL of 20 ppb constitute a CCP that should be monitored with chemicaland microbiological analyses Scheduled inspection and under-plate cleaning canprevent insufficient separation of trub from wort (23)
Boiling (CCP5)
Wort is boiled for up to 2 h at atmospheric pressure following the additionof hops (CCP) The shape of copper boiling time and temperature can affect thequality of produced beer The major objectives of wort boiling are a) wort steril-ization and enzyme inactivation b) extraction of bitter and other substances fromhops and formation of flavor compounds and c) evaporation of excess water andwort concentration evaporation of undesirable flavour volatiles Wort contamina-tion of the wort with Enterobacteriaceae from hops can result in various off-flavorsincluding ldquovegetablerdquo and ldquophenolicrdquo taints (24) Correct use of boiler treatmentchemicals steam condensate tasting for carrying over the taints and operation of
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ORDER REPRINTS
12 KOURTIS AND ARVANITOYANNIS
phenol analyses are all essential to avoid chemical contamination and taints devel-opment (23)
Clarification
Wort clarification is conducted either through sedimentation or filtrationWhen whole hop cones are used it is necessary to employ either a hop back ora hop separatorndashfilter The drop in hop usage and the widespread acceptance ofpreisomerized extracts led to utilization of a vertical cylinder known as whirlpoolwhich induces sustainable circulation of the trub collecting as a compact cone in thebase Whirlpools are more suited to larger worts and can also be used with ale Inmodern breweries centrifuges constitute a promising alternative to whirlpools (25)
Cooling
To prepare for fermentation the clear hopped wort is cooled usually in aplate heat exchanger During cooling it is advisable to aerate or even to oxygenatethe wort because next processing step involves yeast growth promoted in the pres-ence of dissolved oxygen despite the low dissolved oxygen concentration in wort(7ndash14 ppm) (22)
Fermentation (CCP6)
Fermentation aims at producing ethanol by fermenting yeasts Yeasts vary intheir behavior during fermentation some strains tend to flocculate trap plug CO2 andrising to the top whereas others do not flocculate and precipitate Several lagers areproduced by bottom fermentation while many types of ales and stouts are producedby top fermentation Saccharomyces cerevisiae is usually the top fermenting yeastin the range of 18ndash22C whilst the bottom-fermenting are strains of Saccharomycesuvarum that function in the range of 7ndash15C (26) Therefore the temperature atwhich fermentation occurs is very crucial for the further stages of beer productionThe modern use of cylindroconical vessels has reduced the fermentation periodfor ales and lagers from 7 to 2 or 3 days and from 10 to 7 days respectively (27)Fermentation is monitored by taking samples for measuring the specific gravityand can be controlled by varying the cooling rate (20) ldquoStuckrdquo fermentation wherethe required ethanol level is not attained and microbial contamination with Lacticacid bacteria mainly Lactobacilii and Pediococcus which cause taints duringmaturation or in bottle storage (28) represent microbiological hazards which arethe only hazard detected at this stage Common causes for ldquostuckrdquo fermentationinclude premature yeast flocculation and yeast failure to metabolize maltotriosedue to repression by glucose (25) A minimum of 90 viable yeast cells (CL) canbe applied to ensure the development of the process During fermentation the pH
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 13
drops from 52 to 42 and by its completion the yeast is removed either as a top orbottom crop and retained to pitch the next fermentation Apart from the conventionalmicrobial detection methods with plate count several rapid detection methodspotentially applied in breweries such as ATP bioluminescence flow cytometryand polymerase chain reaction have been developed to reduce the incubation timefrom 3ndash4 days to 1ndash2 (2930)
Maturation
Maturation includes all those changes occurring between the end of primaryfermentation to beer filtration (31) Ale is matured at relatively warm temperatures12ndash20C while lagers are held under much cooler conditions The warmer temper-atures allow the rapid metabolism of any residual and priming sugars as well asloss of green flavors within 1ndash2 weeks depending on beer type yeast strain wortcomposition and primary fermentation conditions In case of lager the beer used tobe held at refrigerated temperatures for up to several months after fermentation al-lowing formation of proteintannin complexes (18) Today the enzyme addition hassubstantially shortened this process to several weeks during which flavor maturesEnzymes such as papain may be added during transfer between fermentation andmaturation tank The dosage of the proteolytic enzyme varies depending on typeof beer and process Enzyme activity decreases progressively during maturationuntil its inactivation with pasteurization Part of the enzyme absorbed in the yeastsurface is removed during filtration (19)
Filtration (CCP7)
Beer produced during fermentation is turbid and should be clarified prior to itsmarketing This turbidity is due to the presence of yeasts and proteinaceous materi-als associated with carbohydrates and polyphenols The formation of these proteinprecipitates is attributed to cold temperature low pH and poor solubility in alcoholicsolutions (32) To prevent this from occurring in the final product the beer may besubjected to various chill-proofing treatments during its storage These treatmentsgenerally include the addition of clays to absorb the colloidal materials or prote-olytic enzymes used to further solubilize the protein fraction (33) Since oxygenuptake during this process could severely affect the product organoleptic charac-teristics a CCP of dissolved oxygen should be applied with a CL of 02 ppm (34)
Packaging and Sealing
The packing section comprises several CCPs including the containers to beused their cleaning and disinfection (CCP8) the filler line (CCP9) and the sealer(CCP10) The bursting pressure of the bottles as guaranteed by the manufacturerin his specifications for the new glass may no longer be valid in case of reusable
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ORDER REPRINTS
14 KOURTIS AND ARVANITOYANNIS
bottles due to the considerable physical stress during already exerted upon themduring the filling process Insufficient cleaning of reusable bottles due to low temper-atures and concentrations of the employed cleaning solutions as well as presence ofextraneous entrapped materials within bottles and improper emptying consist pos-sible hazards Moreover cleaning solution remnants and shards introduced throughthe procedure pose problems under working conditions The beer filler may be con-taminated by cleaning and disinfection solutions Contamination sources may bedue to inadequate pressure or faulty CIP system resulting in cleaning and disinfect-ing solution remains in the pressure tank or the ring bowl of the filler (3536) Thecrown corker should be correctly installed the filling pressure of bottle caps on themouths of the bottles should be adjusted to ensure a specified blow-off effect toavoid bottle bursting After filling there should be a full bottle inspector detectingglass particles in bottles or possible leakage (37)
Bottle Pasteurization (CCP11)
Pasteurization is carried out to ensure the beer shelf life over a period ofmonths This is accomplished by the development of tunnel pasteurization in whichthe beer bottle is subjected to 60C for 20 min Over-pasteurization which causesoxidation and can adversely affect beer flavor (38) is a potential physical hazardFurthermore it is crucial to check the time-temperature procedure with adequatecorrective actions for assuring the production of a satisfactory product
Bottle Inspection (CCP12)
Bottle inspection after the pasteurization step is important to ensure that bottleshave not been damaged during the process (39) Should such a situation occur theequipment has to be standardized by the production engineer
Labeling and Standardization (CCP13)
Labeling of the package should comply with the requirements of the CodexGeneral for the labeling of prepackaged foods (40) This means that the name of theproduct shall be clearly declared there must be a list of ingredients in descendingorder of proportion no other fruit may be represented pictorially except those usedand ldquothe date of minimum durabilityrdquo will be declared by the month and year inuncoded numerical sequence
BottleCan Packaging (CCP14)
Bottles (cans) are packaged into paperboard boxes of various sizes accordingto the bottle or can dimensions The encountered hazards can be of physical natureconcerning the bottles (cans) condition during the procedure
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 15
Storage (CCP15)
The finished beer undergoes chemical microbiological and organoleptic anal-ysis to ensure that its properties are within its specification range A synoptical pre-sentation of the occurring hazards CCPs CLs and preventive corrective measuresis given in Table 1
SAKE
Introduction
Sake is a fermented liquor made from rice and coming in many varietiesdepending on the raw materials manufacturing process and process after brewing(41) According to the earliest records sake was originally brewed from rice thathad been chewed to reach saccharification followed by natural fermentation Sakebrewed this way was used as a sacred wine in the worship of the Shinto gods Thisassociation with religion Shintoism and Buddhism has caused a deep intertwiningof sake with the traditions and social customs of Japan Thus today sake is servedat ceremonies and celebrations of all kinds (42) Sake has the highest alcoholpercentage by volume of any fermented beverage In its natural undiluted state itmay contain a potent 20 ethanol compared to 3ndash5 for beer or 9ndash12 for winewhich may reach higher values for fortified wines (4344) The central brewersrsquounion divides sake into four basic flavor types on four axes of sweet sour bitterand umai The latter is another translatorrsquos nightmare which generally ends uptranslated as delicious According to position established along these axes sakeis considered to be of ldquomature typerdquo ldquofragrant typerdquo ldquolight and smooth typerdquo orldquofull-bodied typerdquo (Fig 3) However no set of criteria can adequately express themultiplicity of sensations that together create the flavor unique to any individualsake but there is a perceived need for terms which quickly and simply give thegeneral idea
Figure 3 Main flavor types for sake characterization (43)
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ORDER REPRINTS
16 KOURTIS AND ARVANITOYANNIS
Sake Main Production Stages
The main stages for sake production are schematically presented in Figure 4
Raw Materials (CCP1)
The main ingredients of Japanese sake are rice sake rice sake yeastand water The rice most suitable for sake should consist of large grains and shouldbe soft with a white part at its center due to coarse cell structure Rice should complywith the maximum residue limits for pesticides and insecticides established by theCodex Alimentarius Commission for this commodity (45) (CCP chemical hazard)For Japanese sake yellow koji mold (Aspergillus oryzae) is used Sake yeast (Sac-charomyces cerevisiae) is a microbe converting the occurring glucose and mineralsin rice and water into alcohol Employment of bubble-free type yeast eliminates
Figure 4 Process flow diagram of sake production (264647)
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 17
the bubble removal step thus shortening the brewing period and reducing the costShould the factory wish to employ a specific yeast an adequate disinfection ofthe building interior is required otherwise undesirable bacteria may be introducedwhich could prove hazardous to human health (CCP microbiological hazard) (46)
Rice Polishing (CCP2)
The brown rice used for sake production must be first polished to remove theouter portion of the grain which contains fats proteins minerals and amino acidsthat can cause unpleasant flavors leaving the starch residues that are located in thecenter of the grain Nowadays machines are programmed to automatically removewhatever portion of the rice is required for the specific sake (47) The rice polishingratio (73ndash35) is expressed by the following formula (43)
Rice polishing ratio=(weight of white riceweight of brown rice)times100 (1)
The polishing process should be gently carried out because friction results inheat generation thereby greatly affecting water absorption and rice grain structureBroken grains are unlikely to satisfactorily ferment (47) Maybe the most importantstage in sake production consists of yeast starter mash production which can takeplace either with the classical Kimoto or slightly revised Yamahai process or withthe new ldquohigh speedrdquo methods (48)
Washing (CCP3)
After the rice has been polished rice powder clinging to the grain surface isremoved by washing Washing can be carried out either mechanically or manually(laborious hand washing) and should result in removing most of the organic andinorganic impurities reaching the CLs set by Codex Alimentarius of 15 and01 mm respectively
Soaking (Steeping)
Soaking allows rice to absorb the desired amount of water that is crucial toestablishing the rice consistency For sake produced ldquoen masserdquo simply dumpinginto a vat overnight for as long as 14 h is a usual case (47) However high polishedrice may be soaked within minutes In such a case an error of a minute might proveto have dire consequences for the end product (43)
Steaming (CCP4)
Steaming aims at softening the rice grains and breaking down the starchmolecules thus encouraging the growth of Aspergillus oryzae and eliminating all
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ORDER REPRINTS
18 KOURTIS AND ARVANITOYANNIS
other microorganisms leaving an initially sterile environment prone to sake moldpropagation Presence of lactic acid bacteria (LAB) and yeasts may occur at theend of this step representing a microbiological hazard and resulting in consider-able organoleptic losses The time can vary from 20 to 60 min depending on thebrewer and apparatus employed (40ndash60 and 20 min for traditional and automatedrespectively) (4346)
Cooling
The ensuing division of steamed rice is mainly related to its further use Apart of it is directly cooled by air blower whereas 20ndash30 is transferred to a heatedculture room to be infected with bacteria spores (Aspergillus oryzae) for sake moldproduction
Koji
Since rice grains contain no sugar it is the action of koji mold that converts thestarch in the grains to sugar The steamed rice is first cooled to 15ndash36C before beingtransferred to the koji culture room (30C) Spores of the mold are sprinkled likefine dust on the rice when it has cooled down to 33C After the spores are kneadedinto the steamed rice the rice is heaped and wrapped in cloths to prevent heat andmoisture loss which are two crucial factors for satisfactory bacterial growth Tomaintain uniform temperature and moisture rice is spread and mixed twice the firsttime after 20 hours (upon the appearance of white flecks) and then 7ndash8 h thereafteraccompanied by a distinctive aroma release (48)
Main Mash (Moromi) and Fermentation (CCP5)
In fermentation the occurring chemical hazards are related to heavy metalspresence (As lt 02 Cd lt 001 Pb lt 03 mgL) pesticide residues (as mentionedin Codex Alimentarius) and residues of detergents (absence) and ethylene glycole(absence) Their CLs can be determined and monitored with specific chemicalanalyses The ingredients of main mash (water koji rice and steamed rice) areadded to the starter mash in three steps (moving from small to bigger recipient)over a period of 4 days at successively lower temperatures thus preventing thegrowth of airborne bacteria (Table 2) A day after the addition of all the ingredientsformation of a moist surface showing clear cracks occurs Furthermore the mashbegins to bubble (indication of fermentation progress) as gas is given off during theburgeoning fermentation The fermentation can take place at various temperaturesand its duration depends on it that is at lower temperatures it takes up to twoweeks but the sake aroma is much more appealing compared to that formed athigher temperatures The characteristic sake aroma results from combined flavor
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 19
Table 2 Quantities of Ingredients at Each Stage of Mixing the Main Mash (Moromi)
Yeast 1st 2nd 3rd 4thStarter (Moto) Addition Addition Addition Additiona Total
Total rice (kg) 210 470 850 1470 3000Steamed rice (kg) 140 330 650 1230 2350Koji rice (kg) 70 140 200 240 65030 Brewerrsquos 1200 1200
alcohol (L)Water (L) 230 420 1010 2030 360 405
aTraditional brewers mix the final mash in three stages The fourth addition of alcohol and wateris a controversial postwar development (Kondo 1984)
components of a number of compounds produced during fermentation (49) Theelevated alcohol content of the fermented sake is related to lipid metabolism ofyeast in the presence of proteolipid provided by the koji molds (5051)
Additions (CCP6)
The addition of alcohol at this stage is carried out unless it is clearly statedthat sake does not contain any alcohol from extraneous sources The added alcoholshould not contain methanol or if it does the content of the latter should be lessthan 05 gL because of its toxicity (CCP chemical hazard)
Pressing
Automatic machine presses (consisting of a series of panels with balloon-likesacks attached) are most widely used nowadays instead of the traditional time-consuming method using long bags The remained caked lees are employed forpickle production and cooking or sedimentation of rice particles may occur Alter-natively sedimentation of rice particles at the bottom of the tank may take place
Filtration
Coloring and aging (maturation) inhibition can be effected by using activatedcharcoal filters
Pasteurization (CCP7 and CCP8)
Heating sake preferably twice at 65C kills off the remaining yeast stops en-zyme action and deactivates the lactic acid bacteria that will eventually spoil sakeThis process represents a microbiological hazard for which the specific plant may
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ORDER REPRINTS
20 KOURTIS AND ARVANITOYANNIS
set CLs However in recent years refrigerated storage and transport have madeunpasteurized sake with characteristic aroma available to the consumer (43)
Dilution
The produced sake in its raw state (Genchu) contains more than 20 alcoholby volume but it is generally diluted to about 15ndash16 vol-
BottlingStorageDistribution
The applied procedures are similar to those mentioned for the beer productionA summary of the occurring hazards CCPs CLs and preventive and correc-
tive measures is given in Table 3
WINE
Introduction
Wines are made from the fruit of Vitis vinifera of which there are a greatnumber of varieties growing in many parts of the world The history of wine isinextricably interwoven with human history It might be as true to say that it waswith wine that civilization began for the vine takes longer to mature than any othercrop and does not produce grapes for wine making until its fourth year It is notexactly known when men first had wine but it was accepted as a gift from the godsthe Egyptians attributed it to Osiris and the Greeks to Dionysos Mesopotamia andthe Caucasian slopes were no doubt early sources of wine from where it was spreadto Egypt and Greece and then to the rest of the world (52)
Wine Main Production Stages
The main stages for wine production are schematically presented in Figure 5
Harvesting (CCP1)
Grape harvesting is a CCP comprising both physical and chemical hazardsPhysically the grapes should be sound without rotten parts otherwise oxidativeand microbial contamination can rapidly develop Therefore harvesting shouldbe conducted with the greatest possible care and an efficient disease managementsystem should be applied (5354) Pesticides play an important role in pest man-agement but they should be handled with care because they constitute chemicalhazards (55) At the time of harvest the grapes must have also reached the correctmaturity when Brix and Total Acidity (TA) levels indicate maturity of wine Sincepesticide and fungicide residues on the surface of the berries constitute chemical
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 21
hazards Oliva et al (56) proposed a rapid and simple gas chromatographic methodfor their determination The maximum residue limits for pesticides in grapes andwines are provided by Codex Alimentarius (45) and Organisation International duVin (57) Finally the bulk bins used for grapes transportation should be effectivelydecontaminated to avoid any microbial infection
Stemming
Stemming includes the removal of stem leaves and grape stalks before crush-ing This procedure has several advantages because the total volume of processedproduct drops by 30 thus resulting in smaller tanks and eventually increasingthe productrsquos alcoholic content (58) However the end of fermentation and the al-cohol content of finished product depend mostly on the Brix level of initial grapesStemmers usually contain a perforated cylinder allowing berries to pass throughbut prevent the passage of stems stalks and leaves
Crushing
Crushing typically immediately follows stemming since some crushing ofthe fruit occurs during stemming The released juice is highly susceptible to oxida-tive browning and microbial contamination The most common crushing processesinvolve pressing the fruit against a perforated wall or passing the fruit through a setof rollers It is very important to avoid crushing the seeds to preclude contaminat-ing the must with seed oils the oxidation of which could produce rancid odors andconstitute an undesirable source of bitter tannins Equally important is the properhandling of product because inappropriate timing might lead to a sudden startof alcoholic fermentation and consequently to higher fermentation temperatureswhile a delay might cause microbial contamination and oxidative browning (59)
Maceration
Maceration is the breakdown of grape solids after crushing of grapes Whilemaceration is always involved in the initial stage of red wine fermentation the long-standing trend has been to limit maceration in white wine production Temperatureand duration of maceration depend on grape and wine variety Usually for white androse wines the maceration time is less than 24 h red destined for early consumptionis macerated for 3ndash5 days and red for aging is macerated from 5 days to 3 weeksFermentation usually occurs during this or at the end of maceration The amount ofthe antimicrobial to be used usually added to white musts that are most sensitive tooxidation depends on the crop health and maceration temperature Sulfur dioxidehas a distinct advantage over other antimicrobial agents because of the relativeinsensitivity of the wine yeasts to its action However it is also toxic or inhibitoryto most bacteria and yeasts (ie Candida Pichia Hansenula) at low concentrations(60) and has a rather low retention capability after the clarification step (61)
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22 KOURTIS AND ARVANITOYANNISTa
ble
3Su
mm
ary
ofH
azar
dsC
CPs
CL
sM
onito
ring
Cor
rect
ive
Act
ions
and
Pers
onne
lRes
pons
ible
for
Sake
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
a(M
CP
)bM
easu
res
CC
PPa
ram
eter
(CL
s)Pr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
CC
ertifi
edsu
pplie
rs
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
wat
er
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Cer
tified
supp
liers
Hea
vym
etal
spr
esen
cein
wat
er
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Eva
luat
ion
ofth
ede
cont
amin
atin
gm
etho
ds
MC
ertifi
edsu
pplie
rs
prop
erpr
epar
atio
n
Mic
robi
alco
ntam
inat
ion
ofth
ecu
lture
100
clea
nM
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Wat
erm
icro
biol
ogic
alqu
ality
Abs
ence
ofpa
thog
ens
Insp
ectio
nof
the
equi
pmen
t
Ric
epo
lishi
ng(C
CP2
)C
Cer
tified
supp
lier
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
polis
hed
rice
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Was
hing
(CC
P3)
PC
ertifi
edsu
pplie
rs
inst
alla
tion
ofau
tom
atic
sepa
rato
r
Ani
mal
impu
ritie
sO
ther
orga
nic
and
inor
gani
cm
ater
01
mm
15
mm
01
mm
Spec
ific
exam
inat
ion
Rew
ashi
ngof
spec
ific
batc
hch
ange
supp
lier
Qua
lity
cont
rol
man
ager
Stea
min
g(f
orun
past
euri
sed
sake
)(C
CP4
)
MG
MP
sche
dule
dm
icro
biol
ogic
alco
ntro
ls
Pres
ence
ofye
asts
and
LA
B
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Spec
ific
batc
hre
proc
essi
ng
CIP
stan
dar-
disa
tion
Qua
lity
cont
rol
man
ager
T
rain
ned
pers
onne
l
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 23
Ferm
enta
tion
(CC
P5)
CM
ater
ialc
ontr
ol
GM
Pco
rros
ion
chec
ks
Hea
vym
etal
pres
ence
Pest
icid
ere
sidu
es
Aslt
02
Cd
lt
001
Pb
lt
03
(mg
L)
Spec
ific
chem
ical
anal
ysis
Dem
etal
lisat
ion
Cha
nge
supp
lier
Rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
GM
Pus
eof
nont
oxic
glyc
ole
Res
idue
sof
ehty
lene
glyc
ole
ampde
terg
ents
0Sp
ecifi
cch
emic
alan
alys
isD
ilutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Alc
ohol
addi
tion
(CC
P6)
CC
ertifi
edsu
pplie
rM
etha
nolc
onte
ntlt
05
gL
GC
exam
inat
ion
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erPa
steu
riza
tion
(CC
P7amp
CC
P8)
MR
unni
ngof
past
euri
ser
acco
rdin
gto
prog
ram
Det
ectio
nof
yeas
tsL
AB
en
zym
atic
activ
ity
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Tem
pera
ture
adju
stm
ent
batc
hre
proc
essi
ng
prop
erm
achi
nery
disi
nfec
tion
Qua
lity
cont
rol
man
ager
Tech
nica
lm
anag
er
aR
egar
ding
the
proc
edur
esof
bottl
ing
stor
age
and
dist
ribu
tion
the
CC
Psar
esi
mila
rto
thos
em
entio
ned
inTa
ble
1fo
rbe
erpr
oduc
tion
bM
CP
stan
dfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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26 KOURTIS AND ARVANITOYANNIS
Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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ORDER REPRINTS
28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
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ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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ORDER REPRINTS
10 KOURTIS AND ARVANITOYANNIS
than malt are sometimes used as an additional source of extract to supplementmalt Unmalted cereal adjuncts usually contain no active enzymes and thereforerely on malt or exogenous enzymes to provide the necessary enzymes for starchconversion (19)
Yeast growth cannot be separated from the fermentation process and it isnecessary to the production of both beer and fresh yeast for use in subsequentfermentations The quality control of yeasts comprises a) the selection maintenanceand supply of a suitable strain and b) the routine assessment of purity and detectionof microbial contamination (CCP) (20)
Malting (CCP2)
This process involves steeping the barley in a shallow bed of water at a tem-perature of 10ndash15C so that its moisture content amounts to 45 wt- of barleyBarley is then allowed to germinate under controlled temperature conditions atapproximately 15C and RH100 with constant turning to prevent matting therootlets The barleycorn undergoes germination through air passage via the germi-nating malt for 3ndash5 days Gentle heating stops germination due to moisture removaland promotes formation of flavor compounds The kiln temperature regime is cru-cial for the color of malt and the survival of enzymes to be used in the mashingprocess Kilning duration usually varies between 24 and 48 h Time temperatureand moisture content are varied to control color and flavor development Chemicalmicrobiological and physical hazards may be encountered in this step In partic-ular nitrosodimethylamine (NDMA) production during kilning (reaction of NOx
with organic materials) constitutes a chemical hazard with a critical limit (CL) at25 ppb because of its suspected carcinogenic effect In addition mycotoxin pro-duction more than 0004 mgL and color and flavor alteration represent chemicaland physical hazards respectively The NDMA content in malt can be controlled byusing indirect heating systems or by carefully maintained and controlled low-NOx
burners Regular checks should nevertheless be carried out by the maltster so thatthe residual risk caused by polluted air is kept as low as possible (17) The finishedmalt has its rootlets removed and is screened to produce the uniform quality Duringthe malting process two important changes occur a) the barley develops its ownenzyme systems and b) the naturally produced enzymes start to break down the cellstructure of the endosperm (19) Malt quality control tests include hot water extractcolor soluble nitrogen total nitrogen moisture enzyme activities viscosity andlautering prediction tests The microbiological status of malt used in the followingsteps (CCP) is very much dependent on its handling operations after production (16)
Milling
The main function of dry or wet milling is to reduce the malt particle sizeto form grist (ground or milled grain) The particle size reduction facilitates the
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 11
extraction of soluble components mainly sugars and nitrogenous compounds fromthe endosperm (21)
Mashing (CCP3)
Mashing the first step in wort production involves extracting soluble materi-als from the milled malt This is accomplished by feeding the grist through Steelrsquosmasher a hydrator consisting of a large-bore tube bent at right angles During itspassage through the vertical portion of tube the grist is spayed with hot water (typ-ically 65C) and then mixed with the help of a revolving screw (22) The floatingendosperm particles hydrate and undergo further amylolytic scission by α- andβ-amylases Processors adjust the pH and temperature conditions to allow bothenzymes with a range of susceptibility to pH and temperature to work effectivelyNDMA production (CL = 25 ppb) as well as possible detergent residues constitutepotential chemical hazards for public health Continuous monitoring at the process-ing and adjustment of the lautering program and Cleaning In Place (CIP) systemwhen deviation occurs are proper preventive and corrective actions respectively
Lautering (CCP4)
The lauter tun is a vessel normally rinsed thoroughly with a sparging or hotwater delivery system before receiving the mash which precipitates at the flat floorof slotted stainless steel or brass plates At tun center there is a lautering machineon the shaft of which rotating rakes are attached to facilitate draining the wortinto a collection vessel called grant The wort is recirculated through the lauter tununtil it reaches a certain degree of clarity whereupon it is delivered to the kettle(21) In lautering production of Apparent Total N-nitroso compounds (ATNC)above the CL of 20 ppb constitute a CCP that should be monitored with chemicaland microbiological analyses Scheduled inspection and under-plate cleaning canprevent insufficient separation of trub from wort (23)
Boiling (CCP5)
Wort is boiled for up to 2 h at atmospheric pressure following the additionof hops (CCP) The shape of copper boiling time and temperature can affect thequality of produced beer The major objectives of wort boiling are a) wort steril-ization and enzyme inactivation b) extraction of bitter and other substances fromhops and formation of flavor compounds and c) evaporation of excess water andwort concentration evaporation of undesirable flavour volatiles Wort contamina-tion of the wort with Enterobacteriaceae from hops can result in various off-flavorsincluding ldquovegetablerdquo and ldquophenolicrdquo taints (24) Correct use of boiler treatmentchemicals steam condensate tasting for carrying over the taints and operation of
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ORDER REPRINTS
12 KOURTIS AND ARVANITOYANNIS
phenol analyses are all essential to avoid chemical contamination and taints devel-opment (23)
Clarification
Wort clarification is conducted either through sedimentation or filtrationWhen whole hop cones are used it is necessary to employ either a hop back ora hop separatorndashfilter The drop in hop usage and the widespread acceptance ofpreisomerized extracts led to utilization of a vertical cylinder known as whirlpoolwhich induces sustainable circulation of the trub collecting as a compact cone in thebase Whirlpools are more suited to larger worts and can also be used with ale Inmodern breweries centrifuges constitute a promising alternative to whirlpools (25)
Cooling
To prepare for fermentation the clear hopped wort is cooled usually in aplate heat exchanger During cooling it is advisable to aerate or even to oxygenatethe wort because next processing step involves yeast growth promoted in the pres-ence of dissolved oxygen despite the low dissolved oxygen concentration in wort(7ndash14 ppm) (22)
Fermentation (CCP6)
Fermentation aims at producing ethanol by fermenting yeasts Yeasts vary intheir behavior during fermentation some strains tend to flocculate trap plug CO2 andrising to the top whereas others do not flocculate and precipitate Several lagers areproduced by bottom fermentation while many types of ales and stouts are producedby top fermentation Saccharomyces cerevisiae is usually the top fermenting yeastin the range of 18ndash22C whilst the bottom-fermenting are strains of Saccharomycesuvarum that function in the range of 7ndash15C (26) Therefore the temperature atwhich fermentation occurs is very crucial for the further stages of beer productionThe modern use of cylindroconical vessels has reduced the fermentation periodfor ales and lagers from 7 to 2 or 3 days and from 10 to 7 days respectively (27)Fermentation is monitored by taking samples for measuring the specific gravityand can be controlled by varying the cooling rate (20) ldquoStuckrdquo fermentation wherethe required ethanol level is not attained and microbial contamination with Lacticacid bacteria mainly Lactobacilii and Pediococcus which cause taints duringmaturation or in bottle storage (28) represent microbiological hazards which arethe only hazard detected at this stage Common causes for ldquostuckrdquo fermentationinclude premature yeast flocculation and yeast failure to metabolize maltotriosedue to repression by glucose (25) A minimum of 90 viable yeast cells (CL) canbe applied to ensure the development of the process During fermentation the pH
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 13
drops from 52 to 42 and by its completion the yeast is removed either as a top orbottom crop and retained to pitch the next fermentation Apart from the conventionalmicrobial detection methods with plate count several rapid detection methodspotentially applied in breweries such as ATP bioluminescence flow cytometryand polymerase chain reaction have been developed to reduce the incubation timefrom 3ndash4 days to 1ndash2 (2930)
Maturation
Maturation includes all those changes occurring between the end of primaryfermentation to beer filtration (31) Ale is matured at relatively warm temperatures12ndash20C while lagers are held under much cooler conditions The warmer temper-atures allow the rapid metabolism of any residual and priming sugars as well asloss of green flavors within 1ndash2 weeks depending on beer type yeast strain wortcomposition and primary fermentation conditions In case of lager the beer used tobe held at refrigerated temperatures for up to several months after fermentation al-lowing formation of proteintannin complexes (18) Today the enzyme addition hassubstantially shortened this process to several weeks during which flavor maturesEnzymes such as papain may be added during transfer between fermentation andmaturation tank The dosage of the proteolytic enzyme varies depending on typeof beer and process Enzyme activity decreases progressively during maturationuntil its inactivation with pasteurization Part of the enzyme absorbed in the yeastsurface is removed during filtration (19)
Filtration (CCP7)
Beer produced during fermentation is turbid and should be clarified prior to itsmarketing This turbidity is due to the presence of yeasts and proteinaceous materi-als associated with carbohydrates and polyphenols The formation of these proteinprecipitates is attributed to cold temperature low pH and poor solubility in alcoholicsolutions (32) To prevent this from occurring in the final product the beer may besubjected to various chill-proofing treatments during its storage These treatmentsgenerally include the addition of clays to absorb the colloidal materials or prote-olytic enzymes used to further solubilize the protein fraction (33) Since oxygenuptake during this process could severely affect the product organoleptic charac-teristics a CCP of dissolved oxygen should be applied with a CL of 02 ppm (34)
Packaging and Sealing
The packing section comprises several CCPs including the containers to beused their cleaning and disinfection (CCP8) the filler line (CCP9) and the sealer(CCP10) The bursting pressure of the bottles as guaranteed by the manufacturerin his specifications for the new glass may no longer be valid in case of reusable
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ORDER REPRINTS
14 KOURTIS AND ARVANITOYANNIS
bottles due to the considerable physical stress during already exerted upon themduring the filling process Insufficient cleaning of reusable bottles due to low temper-atures and concentrations of the employed cleaning solutions as well as presence ofextraneous entrapped materials within bottles and improper emptying consist pos-sible hazards Moreover cleaning solution remnants and shards introduced throughthe procedure pose problems under working conditions The beer filler may be con-taminated by cleaning and disinfection solutions Contamination sources may bedue to inadequate pressure or faulty CIP system resulting in cleaning and disinfect-ing solution remains in the pressure tank or the ring bowl of the filler (3536) Thecrown corker should be correctly installed the filling pressure of bottle caps on themouths of the bottles should be adjusted to ensure a specified blow-off effect toavoid bottle bursting After filling there should be a full bottle inspector detectingglass particles in bottles or possible leakage (37)
Bottle Pasteurization (CCP11)
Pasteurization is carried out to ensure the beer shelf life over a period ofmonths This is accomplished by the development of tunnel pasteurization in whichthe beer bottle is subjected to 60C for 20 min Over-pasteurization which causesoxidation and can adversely affect beer flavor (38) is a potential physical hazardFurthermore it is crucial to check the time-temperature procedure with adequatecorrective actions for assuring the production of a satisfactory product
Bottle Inspection (CCP12)
Bottle inspection after the pasteurization step is important to ensure that bottleshave not been damaged during the process (39) Should such a situation occur theequipment has to be standardized by the production engineer
Labeling and Standardization (CCP13)
Labeling of the package should comply with the requirements of the CodexGeneral for the labeling of prepackaged foods (40) This means that the name of theproduct shall be clearly declared there must be a list of ingredients in descendingorder of proportion no other fruit may be represented pictorially except those usedand ldquothe date of minimum durabilityrdquo will be declared by the month and year inuncoded numerical sequence
BottleCan Packaging (CCP14)
Bottles (cans) are packaged into paperboard boxes of various sizes accordingto the bottle or can dimensions The encountered hazards can be of physical natureconcerning the bottles (cans) condition during the procedure
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 15
Storage (CCP15)
The finished beer undergoes chemical microbiological and organoleptic anal-ysis to ensure that its properties are within its specification range A synoptical pre-sentation of the occurring hazards CCPs CLs and preventive corrective measuresis given in Table 1
SAKE
Introduction
Sake is a fermented liquor made from rice and coming in many varietiesdepending on the raw materials manufacturing process and process after brewing(41) According to the earliest records sake was originally brewed from rice thathad been chewed to reach saccharification followed by natural fermentation Sakebrewed this way was used as a sacred wine in the worship of the Shinto gods Thisassociation with religion Shintoism and Buddhism has caused a deep intertwiningof sake with the traditions and social customs of Japan Thus today sake is servedat ceremonies and celebrations of all kinds (42) Sake has the highest alcoholpercentage by volume of any fermented beverage In its natural undiluted state itmay contain a potent 20 ethanol compared to 3ndash5 for beer or 9ndash12 for winewhich may reach higher values for fortified wines (4344) The central brewersrsquounion divides sake into four basic flavor types on four axes of sweet sour bitterand umai The latter is another translatorrsquos nightmare which generally ends uptranslated as delicious According to position established along these axes sakeis considered to be of ldquomature typerdquo ldquofragrant typerdquo ldquolight and smooth typerdquo orldquofull-bodied typerdquo (Fig 3) However no set of criteria can adequately express themultiplicity of sensations that together create the flavor unique to any individualsake but there is a perceived need for terms which quickly and simply give thegeneral idea
Figure 3 Main flavor types for sake characterization (43)
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ORDER REPRINTS
16 KOURTIS AND ARVANITOYANNIS
Sake Main Production Stages
The main stages for sake production are schematically presented in Figure 4
Raw Materials (CCP1)
The main ingredients of Japanese sake are rice sake rice sake yeastand water The rice most suitable for sake should consist of large grains and shouldbe soft with a white part at its center due to coarse cell structure Rice should complywith the maximum residue limits for pesticides and insecticides established by theCodex Alimentarius Commission for this commodity (45) (CCP chemical hazard)For Japanese sake yellow koji mold (Aspergillus oryzae) is used Sake yeast (Sac-charomyces cerevisiae) is a microbe converting the occurring glucose and mineralsin rice and water into alcohol Employment of bubble-free type yeast eliminates
Figure 4 Process flow diagram of sake production (264647)
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the bubble removal step thus shortening the brewing period and reducing the costShould the factory wish to employ a specific yeast an adequate disinfection ofthe building interior is required otherwise undesirable bacteria may be introducedwhich could prove hazardous to human health (CCP microbiological hazard) (46)
Rice Polishing (CCP2)
The brown rice used for sake production must be first polished to remove theouter portion of the grain which contains fats proteins minerals and amino acidsthat can cause unpleasant flavors leaving the starch residues that are located in thecenter of the grain Nowadays machines are programmed to automatically removewhatever portion of the rice is required for the specific sake (47) The rice polishingratio (73ndash35) is expressed by the following formula (43)
Rice polishing ratio=(weight of white riceweight of brown rice)times100 (1)
The polishing process should be gently carried out because friction results inheat generation thereby greatly affecting water absorption and rice grain structureBroken grains are unlikely to satisfactorily ferment (47) Maybe the most importantstage in sake production consists of yeast starter mash production which can takeplace either with the classical Kimoto or slightly revised Yamahai process or withthe new ldquohigh speedrdquo methods (48)
Washing (CCP3)
After the rice has been polished rice powder clinging to the grain surface isremoved by washing Washing can be carried out either mechanically or manually(laborious hand washing) and should result in removing most of the organic andinorganic impurities reaching the CLs set by Codex Alimentarius of 15 and01 mm respectively
Soaking (Steeping)
Soaking allows rice to absorb the desired amount of water that is crucial toestablishing the rice consistency For sake produced ldquoen masserdquo simply dumpinginto a vat overnight for as long as 14 h is a usual case (47) However high polishedrice may be soaked within minutes In such a case an error of a minute might proveto have dire consequences for the end product (43)
Steaming (CCP4)
Steaming aims at softening the rice grains and breaking down the starchmolecules thus encouraging the growth of Aspergillus oryzae and eliminating all
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18 KOURTIS AND ARVANITOYANNIS
other microorganisms leaving an initially sterile environment prone to sake moldpropagation Presence of lactic acid bacteria (LAB) and yeasts may occur at theend of this step representing a microbiological hazard and resulting in consider-able organoleptic losses The time can vary from 20 to 60 min depending on thebrewer and apparatus employed (40ndash60 and 20 min for traditional and automatedrespectively) (4346)
Cooling
The ensuing division of steamed rice is mainly related to its further use Apart of it is directly cooled by air blower whereas 20ndash30 is transferred to a heatedculture room to be infected with bacteria spores (Aspergillus oryzae) for sake moldproduction
Koji
Since rice grains contain no sugar it is the action of koji mold that converts thestarch in the grains to sugar The steamed rice is first cooled to 15ndash36C before beingtransferred to the koji culture room (30C) Spores of the mold are sprinkled likefine dust on the rice when it has cooled down to 33C After the spores are kneadedinto the steamed rice the rice is heaped and wrapped in cloths to prevent heat andmoisture loss which are two crucial factors for satisfactory bacterial growth Tomaintain uniform temperature and moisture rice is spread and mixed twice the firsttime after 20 hours (upon the appearance of white flecks) and then 7ndash8 h thereafteraccompanied by a distinctive aroma release (48)
Main Mash (Moromi) and Fermentation (CCP5)
In fermentation the occurring chemical hazards are related to heavy metalspresence (As lt 02 Cd lt 001 Pb lt 03 mgL) pesticide residues (as mentionedin Codex Alimentarius) and residues of detergents (absence) and ethylene glycole(absence) Their CLs can be determined and monitored with specific chemicalanalyses The ingredients of main mash (water koji rice and steamed rice) areadded to the starter mash in three steps (moving from small to bigger recipient)over a period of 4 days at successively lower temperatures thus preventing thegrowth of airborne bacteria (Table 2) A day after the addition of all the ingredientsformation of a moist surface showing clear cracks occurs Furthermore the mashbegins to bubble (indication of fermentation progress) as gas is given off during theburgeoning fermentation The fermentation can take place at various temperaturesand its duration depends on it that is at lower temperatures it takes up to twoweeks but the sake aroma is much more appealing compared to that formed athigher temperatures The characteristic sake aroma results from combined flavor
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 19
Table 2 Quantities of Ingredients at Each Stage of Mixing the Main Mash (Moromi)
Yeast 1st 2nd 3rd 4thStarter (Moto) Addition Addition Addition Additiona Total
Total rice (kg) 210 470 850 1470 3000Steamed rice (kg) 140 330 650 1230 2350Koji rice (kg) 70 140 200 240 65030 Brewerrsquos 1200 1200
alcohol (L)Water (L) 230 420 1010 2030 360 405
aTraditional brewers mix the final mash in three stages The fourth addition of alcohol and wateris a controversial postwar development (Kondo 1984)
components of a number of compounds produced during fermentation (49) Theelevated alcohol content of the fermented sake is related to lipid metabolism ofyeast in the presence of proteolipid provided by the koji molds (5051)
Additions (CCP6)
The addition of alcohol at this stage is carried out unless it is clearly statedthat sake does not contain any alcohol from extraneous sources The added alcoholshould not contain methanol or if it does the content of the latter should be lessthan 05 gL because of its toxicity (CCP chemical hazard)
Pressing
Automatic machine presses (consisting of a series of panels with balloon-likesacks attached) are most widely used nowadays instead of the traditional time-consuming method using long bags The remained caked lees are employed forpickle production and cooking or sedimentation of rice particles may occur Alter-natively sedimentation of rice particles at the bottom of the tank may take place
Filtration
Coloring and aging (maturation) inhibition can be effected by using activatedcharcoal filters
Pasteurization (CCP7 and CCP8)
Heating sake preferably twice at 65C kills off the remaining yeast stops en-zyme action and deactivates the lactic acid bacteria that will eventually spoil sakeThis process represents a microbiological hazard for which the specific plant may
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20 KOURTIS AND ARVANITOYANNIS
set CLs However in recent years refrigerated storage and transport have madeunpasteurized sake with characteristic aroma available to the consumer (43)
Dilution
The produced sake in its raw state (Genchu) contains more than 20 alcoholby volume but it is generally diluted to about 15ndash16 vol-
BottlingStorageDistribution
The applied procedures are similar to those mentioned for the beer productionA summary of the occurring hazards CCPs CLs and preventive and correc-
tive measures is given in Table 3
WINE
Introduction
Wines are made from the fruit of Vitis vinifera of which there are a greatnumber of varieties growing in many parts of the world The history of wine isinextricably interwoven with human history It might be as true to say that it waswith wine that civilization began for the vine takes longer to mature than any othercrop and does not produce grapes for wine making until its fourth year It is notexactly known when men first had wine but it was accepted as a gift from the godsthe Egyptians attributed it to Osiris and the Greeks to Dionysos Mesopotamia andthe Caucasian slopes were no doubt early sources of wine from where it was spreadto Egypt and Greece and then to the rest of the world (52)
Wine Main Production Stages
The main stages for wine production are schematically presented in Figure 5
Harvesting (CCP1)
Grape harvesting is a CCP comprising both physical and chemical hazardsPhysically the grapes should be sound without rotten parts otherwise oxidativeand microbial contamination can rapidly develop Therefore harvesting shouldbe conducted with the greatest possible care and an efficient disease managementsystem should be applied (5354) Pesticides play an important role in pest man-agement but they should be handled with care because they constitute chemicalhazards (55) At the time of harvest the grapes must have also reached the correctmaturity when Brix and Total Acidity (TA) levels indicate maturity of wine Sincepesticide and fungicide residues on the surface of the berries constitute chemical
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 21
hazards Oliva et al (56) proposed a rapid and simple gas chromatographic methodfor their determination The maximum residue limits for pesticides in grapes andwines are provided by Codex Alimentarius (45) and Organisation International duVin (57) Finally the bulk bins used for grapes transportation should be effectivelydecontaminated to avoid any microbial infection
Stemming
Stemming includes the removal of stem leaves and grape stalks before crush-ing This procedure has several advantages because the total volume of processedproduct drops by 30 thus resulting in smaller tanks and eventually increasingthe productrsquos alcoholic content (58) However the end of fermentation and the al-cohol content of finished product depend mostly on the Brix level of initial grapesStemmers usually contain a perforated cylinder allowing berries to pass throughbut prevent the passage of stems stalks and leaves
Crushing
Crushing typically immediately follows stemming since some crushing ofthe fruit occurs during stemming The released juice is highly susceptible to oxida-tive browning and microbial contamination The most common crushing processesinvolve pressing the fruit against a perforated wall or passing the fruit through a setof rollers It is very important to avoid crushing the seeds to preclude contaminat-ing the must with seed oils the oxidation of which could produce rancid odors andconstitute an undesirable source of bitter tannins Equally important is the properhandling of product because inappropriate timing might lead to a sudden startof alcoholic fermentation and consequently to higher fermentation temperatureswhile a delay might cause microbial contamination and oxidative browning (59)
Maceration
Maceration is the breakdown of grape solids after crushing of grapes Whilemaceration is always involved in the initial stage of red wine fermentation the long-standing trend has been to limit maceration in white wine production Temperatureand duration of maceration depend on grape and wine variety Usually for white androse wines the maceration time is less than 24 h red destined for early consumptionis macerated for 3ndash5 days and red for aging is macerated from 5 days to 3 weeksFermentation usually occurs during this or at the end of maceration The amount ofthe antimicrobial to be used usually added to white musts that are most sensitive tooxidation depends on the crop health and maceration temperature Sulfur dioxidehas a distinct advantage over other antimicrobial agents because of the relativeinsensitivity of the wine yeasts to its action However it is also toxic or inhibitoryto most bacteria and yeasts (ie Candida Pichia Hansenula) at low concentrations(60) and has a rather low retention capability after the clarification step (61)
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22 KOURTIS AND ARVANITOYANNISTa
ble
3Su
mm
ary
ofH
azar
dsC
CPs
CL
sM
onito
ring
Cor
rect
ive
Act
ions
and
Pers
onne
lRes
pons
ible
for
Sake
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
a(M
CP
)bM
easu
res
CC
PPa
ram
eter
(CL
s)Pr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
CC
ertifi
edsu
pplie
rs
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
wat
er
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Cer
tified
supp
liers
Hea
vym
etal
spr
esen
cein
wat
er
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Eva
luat
ion
ofth
ede
cont
amin
atin
gm
etho
ds
MC
ertifi
edsu
pplie
rs
prop
erpr
epar
atio
n
Mic
robi
alco
ntam
inat
ion
ofth
ecu
lture
100
clea
nM
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Wat
erm
icro
biol
ogic
alqu
ality
Abs
ence
ofpa
thog
ens
Insp
ectio
nof
the
equi
pmen
t
Ric
epo
lishi
ng(C
CP2
)C
Cer
tified
supp
lier
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
polis
hed
rice
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Was
hing
(CC
P3)
PC
ertifi
edsu
pplie
rs
inst
alla
tion
ofau
tom
atic
sepa
rato
r
Ani
mal
impu
ritie
sO
ther
orga
nic
and
inor
gani
cm
ater
01
mm
15
mm
01
mm
Spec
ific
exam
inat
ion
Rew
ashi
ngof
spec
ific
batc
hch
ange
supp
lier
Qua
lity
cont
rol
man
ager
Stea
min
g(f
orun
past
euri
sed
sake
)(C
CP4
)
MG
MP
sche
dule
dm
icro
biol
ogic
alco
ntro
ls
Pres
ence
ofye
asts
and
LA
B
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Spec
ific
batc
hre
proc
essi
ng
CIP
stan
dar-
disa
tion
Qua
lity
cont
rol
man
ager
T
rain
ned
pers
onne
l
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 23
Ferm
enta
tion
(CC
P5)
CM
ater
ialc
ontr
ol
GM
Pco
rros
ion
chec
ks
Hea
vym
etal
pres
ence
Pest
icid
ere
sidu
es
Aslt
02
Cd
lt
001
Pb
lt
03
(mg
L)
Spec
ific
chem
ical
anal
ysis
Dem
etal
lisat
ion
Cha
nge
supp
lier
Rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
GM
Pus
eof
nont
oxic
glyc
ole
Res
idue
sof
ehty
lene
glyc
ole
ampde
terg
ents
0Sp
ecifi
cch
emic
alan
alys
isD
ilutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Alc
ohol
addi
tion
(CC
P6)
CC
ertifi
edsu
pplie
rM
etha
nolc
onte
ntlt
05
gL
GC
exam
inat
ion
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erPa
steu
riza
tion
(CC
P7amp
CC
P8)
MR
unni
ngof
past
euri
ser
acco
rdin
gto
prog
ram
Det
ectio
nof
yeas
tsL
AB
en
zym
atic
activ
ity
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Tem
pera
ture
adju
stm
ent
batc
hre
proc
essi
ng
prop
erm
achi
nery
disi
nfec
tion
Qua
lity
cont
rol
man
ager
Tech
nica
lm
anag
er
aR
egar
ding
the
proc
edur
esof
bottl
ing
stor
age
and
dist
ribu
tion
the
CC
Psar
esi
mila
rto
thos
em
entio
ned
inTa
ble
1fo
rbe
erpr
oduc
tion
bM
CP
stan
dfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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ORDER REPRINTS
28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
Dow
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
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yman
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irel
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vers
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] at
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
nloa
ded
by [
Sule
yman
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irel
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vers
itesi
] at
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56 2
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ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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] at
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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yman
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] at
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
Dow
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 11
extraction of soluble components mainly sugars and nitrogenous compounds fromthe endosperm (21)
Mashing (CCP3)
Mashing the first step in wort production involves extracting soluble materi-als from the milled malt This is accomplished by feeding the grist through Steelrsquosmasher a hydrator consisting of a large-bore tube bent at right angles During itspassage through the vertical portion of tube the grist is spayed with hot water (typ-ically 65C) and then mixed with the help of a revolving screw (22) The floatingendosperm particles hydrate and undergo further amylolytic scission by α- andβ-amylases Processors adjust the pH and temperature conditions to allow bothenzymes with a range of susceptibility to pH and temperature to work effectivelyNDMA production (CL = 25 ppb) as well as possible detergent residues constitutepotential chemical hazards for public health Continuous monitoring at the process-ing and adjustment of the lautering program and Cleaning In Place (CIP) systemwhen deviation occurs are proper preventive and corrective actions respectively
Lautering (CCP4)
The lauter tun is a vessel normally rinsed thoroughly with a sparging or hotwater delivery system before receiving the mash which precipitates at the flat floorof slotted stainless steel or brass plates At tun center there is a lautering machineon the shaft of which rotating rakes are attached to facilitate draining the wortinto a collection vessel called grant The wort is recirculated through the lauter tununtil it reaches a certain degree of clarity whereupon it is delivered to the kettle(21) In lautering production of Apparent Total N-nitroso compounds (ATNC)above the CL of 20 ppb constitute a CCP that should be monitored with chemicaland microbiological analyses Scheduled inspection and under-plate cleaning canprevent insufficient separation of trub from wort (23)
Boiling (CCP5)
Wort is boiled for up to 2 h at atmospheric pressure following the additionof hops (CCP) The shape of copper boiling time and temperature can affect thequality of produced beer The major objectives of wort boiling are a) wort steril-ization and enzyme inactivation b) extraction of bitter and other substances fromhops and formation of flavor compounds and c) evaporation of excess water andwort concentration evaporation of undesirable flavour volatiles Wort contamina-tion of the wort with Enterobacteriaceae from hops can result in various off-flavorsincluding ldquovegetablerdquo and ldquophenolicrdquo taints (24) Correct use of boiler treatmentchemicals steam condensate tasting for carrying over the taints and operation of
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ORDER REPRINTS
12 KOURTIS AND ARVANITOYANNIS
phenol analyses are all essential to avoid chemical contamination and taints devel-opment (23)
Clarification
Wort clarification is conducted either through sedimentation or filtrationWhen whole hop cones are used it is necessary to employ either a hop back ora hop separatorndashfilter The drop in hop usage and the widespread acceptance ofpreisomerized extracts led to utilization of a vertical cylinder known as whirlpoolwhich induces sustainable circulation of the trub collecting as a compact cone in thebase Whirlpools are more suited to larger worts and can also be used with ale Inmodern breweries centrifuges constitute a promising alternative to whirlpools (25)
Cooling
To prepare for fermentation the clear hopped wort is cooled usually in aplate heat exchanger During cooling it is advisable to aerate or even to oxygenatethe wort because next processing step involves yeast growth promoted in the pres-ence of dissolved oxygen despite the low dissolved oxygen concentration in wort(7ndash14 ppm) (22)
Fermentation (CCP6)
Fermentation aims at producing ethanol by fermenting yeasts Yeasts vary intheir behavior during fermentation some strains tend to flocculate trap plug CO2 andrising to the top whereas others do not flocculate and precipitate Several lagers areproduced by bottom fermentation while many types of ales and stouts are producedby top fermentation Saccharomyces cerevisiae is usually the top fermenting yeastin the range of 18ndash22C whilst the bottom-fermenting are strains of Saccharomycesuvarum that function in the range of 7ndash15C (26) Therefore the temperature atwhich fermentation occurs is very crucial for the further stages of beer productionThe modern use of cylindroconical vessels has reduced the fermentation periodfor ales and lagers from 7 to 2 or 3 days and from 10 to 7 days respectively (27)Fermentation is monitored by taking samples for measuring the specific gravityand can be controlled by varying the cooling rate (20) ldquoStuckrdquo fermentation wherethe required ethanol level is not attained and microbial contamination with Lacticacid bacteria mainly Lactobacilii and Pediococcus which cause taints duringmaturation or in bottle storage (28) represent microbiological hazards which arethe only hazard detected at this stage Common causes for ldquostuckrdquo fermentationinclude premature yeast flocculation and yeast failure to metabolize maltotriosedue to repression by glucose (25) A minimum of 90 viable yeast cells (CL) canbe applied to ensure the development of the process During fermentation the pH
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 13
drops from 52 to 42 and by its completion the yeast is removed either as a top orbottom crop and retained to pitch the next fermentation Apart from the conventionalmicrobial detection methods with plate count several rapid detection methodspotentially applied in breweries such as ATP bioluminescence flow cytometryand polymerase chain reaction have been developed to reduce the incubation timefrom 3ndash4 days to 1ndash2 (2930)
Maturation
Maturation includes all those changes occurring between the end of primaryfermentation to beer filtration (31) Ale is matured at relatively warm temperatures12ndash20C while lagers are held under much cooler conditions The warmer temper-atures allow the rapid metabolism of any residual and priming sugars as well asloss of green flavors within 1ndash2 weeks depending on beer type yeast strain wortcomposition and primary fermentation conditions In case of lager the beer used tobe held at refrigerated temperatures for up to several months after fermentation al-lowing formation of proteintannin complexes (18) Today the enzyme addition hassubstantially shortened this process to several weeks during which flavor maturesEnzymes such as papain may be added during transfer between fermentation andmaturation tank The dosage of the proteolytic enzyme varies depending on typeof beer and process Enzyme activity decreases progressively during maturationuntil its inactivation with pasteurization Part of the enzyme absorbed in the yeastsurface is removed during filtration (19)
Filtration (CCP7)
Beer produced during fermentation is turbid and should be clarified prior to itsmarketing This turbidity is due to the presence of yeasts and proteinaceous materi-als associated with carbohydrates and polyphenols The formation of these proteinprecipitates is attributed to cold temperature low pH and poor solubility in alcoholicsolutions (32) To prevent this from occurring in the final product the beer may besubjected to various chill-proofing treatments during its storage These treatmentsgenerally include the addition of clays to absorb the colloidal materials or prote-olytic enzymes used to further solubilize the protein fraction (33) Since oxygenuptake during this process could severely affect the product organoleptic charac-teristics a CCP of dissolved oxygen should be applied with a CL of 02 ppm (34)
Packaging and Sealing
The packing section comprises several CCPs including the containers to beused their cleaning and disinfection (CCP8) the filler line (CCP9) and the sealer(CCP10) The bursting pressure of the bottles as guaranteed by the manufacturerin his specifications for the new glass may no longer be valid in case of reusable
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ORDER REPRINTS
14 KOURTIS AND ARVANITOYANNIS
bottles due to the considerable physical stress during already exerted upon themduring the filling process Insufficient cleaning of reusable bottles due to low temper-atures and concentrations of the employed cleaning solutions as well as presence ofextraneous entrapped materials within bottles and improper emptying consist pos-sible hazards Moreover cleaning solution remnants and shards introduced throughthe procedure pose problems under working conditions The beer filler may be con-taminated by cleaning and disinfection solutions Contamination sources may bedue to inadequate pressure or faulty CIP system resulting in cleaning and disinfect-ing solution remains in the pressure tank or the ring bowl of the filler (3536) Thecrown corker should be correctly installed the filling pressure of bottle caps on themouths of the bottles should be adjusted to ensure a specified blow-off effect toavoid bottle bursting After filling there should be a full bottle inspector detectingglass particles in bottles or possible leakage (37)
Bottle Pasteurization (CCP11)
Pasteurization is carried out to ensure the beer shelf life over a period ofmonths This is accomplished by the development of tunnel pasteurization in whichthe beer bottle is subjected to 60C for 20 min Over-pasteurization which causesoxidation and can adversely affect beer flavor (38) is a potential physical hazardFurthermore it is crucial to check the time-temperature procedure with adequatecorrective actions for assuring the production of a satisfactory product
Bottle Inspection (CCP12)
Bottle inspection after the pasteurization step is important to ensure that bottleshave not been damaged during the process (39) Should such a situation occur theequipment has to be standardized by the production engineer
Labeling and Standardization (CCP13)
Labeling of the package should comply with the requirements of the CodexGeneral for the labeling of prepackaged foods (40) This means that the name of theproduct shall be clearly declared there must be a list of ingredients in descendingorder of proportion no other fruit may be represented pictorially except those usedand ldquothe date of minimum durabilityrdquo will be declared by the month and year inuncoded numerical sequence
BottleCan Packaging (CCP14)
Bottles (cans) are packaged into paperboard boxes of various sizes accordingto the bottle or can dimensions The encountered hazards can be of physical natureconcerning the bottles (cans) condition during the procedure
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 15
Storage (CCP15)
The finished beer undergoes chemical microbiological and organoleptic anal-ysis to ensure that its properties are within its specification range A synoptical pre-sentation of the occurring hazards CCPs CLs and preventive corrective measuresis given in Table 1
SAKE
Introduction
Sake is a fermented liquor made from rice and coming in many varietiesdepending on the raw materials manufacturing process and process after brewing(41) According to the earliest records sake was originally brewed from rice thathad been chewed to reach saccharification followed by natural fermentation Sakebrewed this way was used as a sacred wine in the worship of the Shinto gods Thisassociation with religion Shintoism and Buddhism has caused a deep intertwiningof sake with the traditions and social customs of Japan Thus today sake is servedat ceremonies and celebrations of all kinds (42) Sake has the highest alcoholpercentage by volume of any fermented beverage In its natural undiluted state itmay contain a potent 20 ethanol compared to 3ndash5 for beer or 9ndash12 for winewhich may reach higher values for fortified wines (4344) The central brewersrsquounion divides sake into four basic flavor types on four axes of sweet sour bitterand umai The latter is another translatorrsquos nightmare which generally ends uptranslated as delicious According to position established along these axes sakeis considered to be of ldquomature typerdquo ldquofragrant typerdquo ldquolight and smooth typerdquo orldquofull-bodied typerdquo (Fig 3) However no set of criteria can adequately express themultiplicity of sensations that together create the flavor unique to any individualsake but there is a perceived need for terms which quickly and simply give thegeneral idea
Figure 3 Main flavor types for sake characterization (43)
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16 KOURTIS AND ARVANITOYANNIS
Sake Main Production Stages
The main stages for sake production are schematically presented in Figure 4
Raw Materials (CCP1)
The main ingredients of Japanese sake are rice sake rice sake yeastand water The rice most suitable for sake should consist of large grains and shouldbe soft with a white part at its center due to coarse cell structure Rice should complywith the maximum residue limits for pesticides and insecticides established by theCodex Alimentarius Commission for this commodity (45) (CCP chemical hazard)For Japanese sake yellow koji mold (Aspergillus oryzae) is used Sake yeast (Sac-charomyces cerevisiae) is a microbe converting the occurring glucose and mineralsin rice and water into alcohol Employment of bubble-free type yeast eliminates
Figure 4 Process flow diagram of sake production (264647)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 17
the bubble removal step thus shortening the brewing period and reducing the costShould the factory wish to employ a specific yeast an adequate disinfection ofthe building interior is required otherwise undesirable bacteria may be introducedwhich could prove hazardous to human health (CCP microbiological hazard) (46)
Rice Polishing (CCP2)
The brown rice used for sake production must be first polished to remove theouter portion of the grain which contains fats proteins minerals and amino acidsthat can cause unpleasant flavors leaving the starch residues that are located in thecenter of the grain Nowadays machines are programmed to automatically removewhatever portion of the rice is required for the specific sake (47) The rice polishingratio (73ndash35) is expressed by the following formula (43)
Rice polishing ratio=(weight of white riceweight of brown rice)times100 (1)
The polishing process should be gently carried out because friction results inheat generation thereby greatly affecting water absorption and rice grain structureBroken grains are unlikely to satisfactorily ferment (47) Maybe the most importantstage in sake production consists of yeast starter mash production which can takeplace either with the classical Kimoto or slightly revised Yamahai process or withthe new ldquohigh speedrdquo methods (48)
Washing (CCP3)
After the rice has been polished rice powder clinging to the grain surface isremoved by washing Washing can be carried out either mechanically or manually(laborious hand washing) and should result in removing most of the organic andinorganic impurities reaching the CLs set by Codex Alimentarius of 15 and01 mm respectively
Soaking (Steeping)
Soaking allows rice to absorb the desired amount of water that is crucial toestablishing the rice consistency For sake produced ldquoen masserdquo simply dumpinginto a vat overnight for as long as 14 h is a usual case (47) However high polishedrice may be soaked within minutes In such a case an error of a minute might proveto have dire consequences for the end product (43)
Steaming (CCP4)
Steaming aims at softening the rice grains and breaking down the starchmolecules thus encouraging the growth of Aspergillus oryzae and eliminating all
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18 KOURTIS AND ARVANITOYANNIS
other microorganisms leaving an initially sterile environment prone to sake moldpropagation Presence of lactic acid bacteria (LAB) and yeasts may occur at theend of this step representing a microbiological hazard and resulting in consider-able organoleptic losses The time can vary from 20 to 60 min depending on thebrewer and apparatus employed (40ndash60 and 20 min for traditional and automatedrespectively) (4346)
Cooling
The ensuing division of steamed rice is mainly related to its further use Apart of it is directly cooled by air blower whereas 20ndash30 is transferred to a heatedculture room to be infected with bacteria spores (Aspergillus oryzae) for sake moldproduction
Koji
Since rice grains contain no sugar it is the action of koji mold that converts thestarch in the grains to sugar The steamed rice is first cooled to 15ndash36C before beingtransferred to the koji culture room (30C) Spores of the mold are sprinkled likefine dust on the rice when it has cooled down to 33C After the spores are kneadedinto the steamed rice the rice is heaped and wrapped in cloths to prevent heat andmoisture loss which are two crucial factors for satisfactory bacterial growth Tomaintain uniform temperature and moisture rice is spread and mixed twice the firsttime after 20 hours (upon the appearance of white flecks) and then 7ndash8 h thereafteraccompanied by a distinctive aroma release (48)
Main Mash (Moromi) and Fermentation (CCP5)
In fermentation the occurring chemical hazards are related to heavy metalspresence (As lt 02 Cd lt 001 Pb lt 03 mgL) pesticide residues (as mentionedin Codex Alimentarius) and residues of detergents (absence) and ethylene glycole(absence) Their CLs can be determined and monitored with specific chemicalanalyses The ingredients of main mash (water koji rice and steamed rice) areadded to the starter mash in three steps (moving from small to bigger recipient)over a period of 4 days at successively lower temperatures thus preventing thegrowth of airborne bacteria (Table 2) A day after the addition of all the ingredientsformation of a moist surface showing clear cracks occurs Furthermore the mashbegins to bubble (indication of fermentation progress) as gas is given off during theburgeoning fermentation The fermentation can take place at various temperaturesand its duration depends on it that is at lower temperatures it takes up to twoweeks but the sake aroma is much more appealing compared to that formed athigher temperatures The characteristic sake aroma results from combined flavor
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 19
Table 2 Quantities of Ingredients at Each Stage of Mixing the Main Mash (Moromi)
Yeast 1st 2nd 3rd 4thStarter (Moto) Addition Addition Addition Additiona Total
Total rice (kg) 210 470 850 1470 3000Steamed rice (kg) 140 330 650 1230 2350Koji rice (kg) 70 140 200 240 65030 Brewerrsquos 1200 1200
alcohol (L)Water (L) 230 420 1010 2030 360 405
aTraditional brewers mix the final mash in three stages The fourth addition of alcohol and wateris a controversial postwar development (Kondo 1984)
components of a number of compounds produced during fermentation (49) Theelevated alcohol content of the fermented sake is related to lipid metabolism ofyeast in the presence of proteolipid provided by the koji molds (5051)
Additions (CCP6)
The addition of alcohol at this stage is carried out unless it is clearly statedthat sake does not contain any alcohol from extraneous sources The added alcoholshould not contain methanol or if it does the content of the latter should be lessthan 05 gL because of its toxicity (CCP chemical hazard)
Pressing
Automatic machine presses (consisting of a series of panels with balloon-likesacks attached) are most widely used nowadays instead of the traditional time-consuming method using long bags The remained caked lees are employed forpickle production and cooking or sedimentation of rice particles may occur Alter-natively sedimentation of rice particles at the bottom of the tank may take place
Filtration
Coloring and aging (maturation) inhibition can be effected by using activatedcharcoal filters
Pasteurization (CCP7 and CCP8)
Heating sake preferably twice at 65C kills off the remaining yeast stops en-zyme action and deactivates the lactic acid bacteria that will eventually spoil sakeThis process represents a microbiological hazard for which the specific plant may
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ORDER REPRINTS
20 KOURTIS AND ARVANITOYANNIS
set CLs However in recent years refrigerated storage and transport have madeunpasteurized sake with characteristic aroma available to the consumer (43)
Dilution
The produced sake in its raw state (Genchu) contains more than 20 alcoholby volume but it is generally diluted to about 15ndash16 vol-
BottlingStorageDistribution
The applied procedures are similar to those mentioned for the beer productionA summary of the occurring hazards CCPs CLs and preventive and correc-
tive measures is given in Table 3
WINE
Introduction
Wines are made from the fruit of Vitis vinifera of which there are a greatnumber of varieties growing in many parts of the world The history of wine isinextricably interwoven with human history It might be as true to say that it waswith wine that civilization began for the vine takes longer to mature than any othercrop and does not produce grapes for wine making until its fourth year It is notexactly known when men first had wine but it was accepted as a gift from the godsthe Egyptians attributed it to Osiris and the Greeks to Dionysos Mesopotamia andthe Caucasian slopes were no doubt early sources of wine from where it was spreadto Egypt and Greece and then to the rest of the world (52)
Wine Main Production Stages
The main stages for wine production are schematically presented in Figure 5
Harvesting (CCP1)
Grape harvesting is a CCP comprising both physical and chemical hazardsPhysically the grapes should be sound without rotten parts otherwise oxidativeand microbial contamination can rapidly develop Therefore harvesting shouldbe conducted with the greatest possible care and an efficient disease managementsystem should be applied (5354) Pesticides play an important role in pest man-agement but they should be handled with care because they constitute chemicalhazards (55) At the time of harvest the grapes must have also reached the correctmaturity when Brix and Total Acidity (TA) levels indicate maturity of wine Sincepesticide and fungicide residues on the surface of the berries constitute chemical
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 21
hazards Oliva et al (56) proposed a rapid and simple gas chromatographic methodfor their determination The maximum residue limits for pesticides in grapes andwines are provided by Codex Alimentarius (45) and Organisation International duVin (57) Finally the bulk bins used for grapes transportation should be effectivelydecontaminated to avoid any microbial infection
Stemming
Stemming includes the removal of stem leaves and grape stalks before crush-ing This procedure has several advantages because the total volume of processedproduct drops by 30 thus resulting in smaller tanks and eventually increasingthe productrsquos alcoholic content (58) However the end of fermentation and the al-cohol content of finished product depend mostly on the Brix level of initial grapesStemmers usually contain a perforated cylinder allowing berries to pass throughbut prevent the passage of stems stalks and leaves
Crushing
Crushing typically immediately follows stemming since some crushing ofthe fruit occurs during stemming The released juice is highly susceptible to oxida-tive browning and microbial contamination The most common crushing processesinvolve pressing the fruit against a perforated wall or passing the fruit through a setof rollers It is very important to avoid crushing the seeds to preclude contaminat-ing the must with seed oils the oxidation of which could produce rancid odors andconstitute an undesirable source of bitter tannins Equally important is the properhandling of product because inappropriate timing might lead to a sudden startof alcoholic fermentation and consequently to higher fermentation temperatureswhile a delay might cause microbial contamination and oxidative browning (59)
Maceration
Maceration is the breakdown of grape solids after crushing of grapes Whilemaceration is always involved in the initial stage of red wine fermentation the long-standing trend has been to limit maceration in white wine production Temperatureand duration of maceration depend on grape and wine variety Usually for white androse wines the maceration time is less than 24 h red destined for early consumptionis macerated for 3ndash5 days and red for aging is macerated from 5 days to 3 weeksFermentation usually occurs during this or at the end of maceration The amount ofthe antimicrobial to be used usually added to white musts that are most sensitive tooxidation depends on the crop health and maceration temperature Sulfur dioxidehas a distinct advantage over other antimicrobial agents because of the relativeinsensitivity of the wine yeasts to its action However it is also toxic or inhibitoryto most bacteria and yeasts (ie Candida Pichia Hansenula) at low concentrations(60) and has a rather low retention capability after the clarification step (61)
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ORDER REPRINTS
22 KOURTIS AND ARVANITOYANNISTa
ble
3Su
mm
ary
ofH
azar
dsC
CPs
CL
sM
onito
ring
Cor
rect
ive
Act
ions
and
Pers
onne
lRes
pons
ible
for
Sake
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
a(M
CP
)bM
easu
res
CC
PPa
ram
eter
(CL
s)Pr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
CC
ertifi
edsu
pplie
rs
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
wat
er
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Cer
tified
supp
liers
Hea
vym
etal
spr
esen
cein
wat
er
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Eva
luat
ion
ofth
ede
cont
amin
atin
gm
etho
ds
MC
ertifi
edsu
pplie
rs
prop
erpr
epar
atio
n
Mic
robi
alco
ntam
inat
ion
ofth
ecu
lture
100
clea
nM
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Wat
erm
icro
biol
ogic
alqu
ality
Abs
ence
ofpa
thog
ens
Insp
ectio
nof
the
equi
pmen
t
Ric
epo
lishi
ng(C
CP2
)C
Cer
tified
supp
lier
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
polis
hed
rice
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Was
hing
(CC
P3)
PC
ertifi
edsu
pplie
rs
inst
alla
tion
ofau
tom
atic
sepa
rato
r
Ani
mal
impu
ritie
sO
ther
orga
nic
and
inor
gani
cm
ater
01
mm
15
mm
01
mm
Spec
ific
exam
inat
ion
Rew
ashi
ngof
spec
ific
batc
hch
ange
supp
lier
Qua
lity
cont
rol
man
ager
Stea
min
g(f
orun
past
euri
sed
sake
)(C
CP4
)
MG
MP
sche
dule
dm
icro
biol
ogic
alco
ntro
ls
Pres
ence
ofye
asts
and
LA
B
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Spec
ific
batc
hre
proc
essi
ng
CIP
stan
dar-
disa
tion
Qua
lity
cont
rol
man
ager
T
rain
ned
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 23
Ferm
enta
tion
(CC
P5)
CM
ater
ialc
ontr
ol
GM
Pco
rros
ion
chec
ks
Hea
vym
etal
pres
ence
Pest
icid
ere
sidu
es
Aslt
02
Cd
lt
001
Pb
lt
03
(mg
L)
Spec
ific
chem
ical
anal
ysis
Dem
etal
lisat
ion
Cha
nge
supp
lier
Rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
GM
Pus
eof
nont
oxic
glyc
ole
Res
idue
sof
ehty
lene
glyc
ole
ampde
terg
ents
0Sp
ecifi
cch
emic
alan
alys
isD
ilutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Alc
ohol
addi
tion
(CC
P6)
CC
ertifi
edsu
pplie
rM
etha
nolc
onte
ntlt
05
gL
GC
exam
inat
ion
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erPa
steu
riza
tion
(CC
P7amp
CC
P8)
MR
unni
ngof
past
euri
ser
acco
rdin
gto
prog
ram
Det
ectio
nof
yeas
tsL
AB
en
zym
atic
activ
ity
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Tem
pera
ture
adju
stm
ent
batc
hre
proc
essi
ng
prop
erm
achi
nery
disi
nfec
tion
Qua
lity
cont
rol
man
ager
Tech
nica
lm
anag
er
aR
egar
ding
the
proc
edur
esof
bottl
ing
stor
age
and
dist
ribu
tion
the
CC
Psar
esi
mila
rto
thos
em
entio
ned
inTa
ble
1fo
rbe
erpr
oduc
tion
bM
CP
stan
dfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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ORDER REPRINTS
26 KOURTIS AND ARVANITOYANNIS
Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
by [
Sule
yman
Dem
irel
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vers
itesi
] at
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ber
2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
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ber
2011
ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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yman
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irel
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] at
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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ded
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yman
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irel
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itesi
] at
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
Dow
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yman
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irel
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itesi
] at
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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irel
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2011
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12 KOURTIS AND ARVANITOYANNIS
phenol analyses are all essential to avoid chemical contamination and taints devel-opment (23)
Clarification
Wort clarification is conducted either through sedimentation or filtrationWhen whole hop cones are used it is necessary to employ either a hop back ora hop separatorndashfilter The drop in hop usage and the widespread acceptance ofpreisomerized extracts led to utilization of a vertical cylinder known as whirlpoolwhich induces sustainable circulation of the trub collecting as a compact cone in thebase Whirlpools are more suited to larger worts and can also be used with ale Inmodern breweries centrifuges constitute a promising alternative to whirlpools (25)
Cooling
To prepare for fermentation the clear hopped wort is cooled usually in aplate heat exchanger During cooling it is advisable to aerate or even to oxygenatethe wort because next processing step involves yeast growth promoted in the pres-ence of dissolved oxygen despite the low dissolved oxygen concentration in wort(7ndash14 ppm) (22)
Fermentation (CCP6)
Fermentation aims at producing ethanol by fermenting yeasts Yeasts vary intheir behavior during fermentation some strains tend to flocculate trap plug CO2 andrising to the top whereas others do not flocculate and precipitate Several lagers areproduced by bottom fermentation while many types of ales and stouts are producedby top fermentation Saccharomyces cerevisiae is usually the top fermenting yeastin the range of 18ndash22C whilst the bottom-fermenting are strains of Saccharomycesuvarum that function in the range of 7ndash15C (26) Therefore the temperature atwhich fermentation occurs is very crucial for the further stages of beer productionThe modern use of cylindroconical vessels has reduced the fermentation periodfor ales and lagers from 7 to 2 or 3 days and from 10 to 7 days respectively (27)Fermentation is monitored by taking samples for measuring the specific gravityand can be controlled by varying the cooling rate (20) ldquoStuckrdquo fermentation wherethe required ethanol level is not attained and microbial contamination with Lacticacid bacteria mainly Lactobacilii and Pediococcus which cause taints duringmaturation or in bottle storage (28) represent microbiological hazards which arethe only hazard detected at this stage Common causes for ldquostuckrdquo fermentationinclude premature yeast flocculation and yeast failure to metabolize maltotriosedue to repression by glucose (25) A minimum of 90 viable yeast cells (CL) canbe applied to ensure the development of the process During fermentation the pH
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 13
drops from 52 to 42 and by its completion the yeast is removed either as a top orbottom crop and retained to pitch the next fermentation Apart from the conventionalmicrobial detection methods with plate count several rapid detection methodspotentially applied in breweries such as ATP bioluminescence flow cytometryand polymerase chain reaction have been developed to reduce the incubation timefrom 3ndash4 days to 1ndash2 (2930)
Maturation
Maturation includes all those changes occurring between the end of primaryfermentation to beer filtration (31) Ale is matured at relatively warm temperatures12ndash20C while lagers are held under much cooler conditions The warmer temper-atures allow the rapid metabolism of any residual and priming sugars as well asloss of green flavors within 1ndash2 weeks depending on beer type yeast strain wortcomposition and primary fermentation conditions In case of lager the beer used tobe held at refrigerated temperatures for up to several months after fermentation al-lowing formation of proteintannin complexes (18) Today the enzyme addition hassubstantially shortened this process to several weeks during which flavor maturesEnzymes such as papain may be added during transfer between fermentation andmaturation tank The dosage of the proteolytic enzyme varies depending on typeof beer and process Enzyme activity decreases progressively during maturationuntil its inactivation with pasteurization Part of the enzyme absorbed in the yeastsurface is removed during filtration (19)
Filtration (CCP7)
Beer produced during fermentation is turbid and should be clarified prior to itsmarketing This turbidity is due to the presence of yeasts and proteinaceous materi-als associated with carbohydrates and polyphenols The formation of these proteinprecipitates is attributed to cold temperature low pH and poor solubility in alcoholicsolutions (32) To prevent this from occurring in the final product the beer may besubjected to various chill-proofing treatments during its storage These treatmentsgenerally include the addition of clays to absorb the colloidal materials or prote-olytic enzymes used to further solubilize the protein fraction (33) Since oxygenuptake during this process could severely affect the product organoleptic charac-teristics a CCP of dissolved oxygen should be applied with a CL of 02 ppm (34)
Packaging and Sealing
The packing section comprises several CCPs including the containers to beused their cleaning and disinfection (CCP8) the filler line (CCP9) and the sealer(CCP10) The bursting pressure of the bottles as guaranteed by the manufacturerin his specifications for the new glass may no longer be valid in case of reusable
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14 KOURTIS AND ARVANITOYANNIS
bottles due to the considerable physical stress during already exerted upon themduring the filling process Insufficient cleaning of reusable bottles due to low temper-atures and concentrations of the employed cleaning solutions as well as presence ofextraneous entrapped materials within bottles and improper emptying consist pos-sible hazards Moreover cleaning solution remnants and shards introduced throughthe procedure pose problems under working conditions The beer filler may be con-taminated by cleaning and disinfection solutions Contamination sources may bedue to inadequate pressure or faulty CIP system resulting in cleaning and disinfect-ing solution remains in the pressure tank or the ring bowl of the filler (3536) Thecrown corker should be correctly installed the filling pressure of bottle caps on themouths of the bottles should be adjusted to ensure a specified blow-off effect toavoid bottle bursting After filling there should be a full bottle inspector detectingglass particles in bottles or possible leakage (37)
Bottle Pasteurization (CCP11)
Pasteurization is carried out to ensure the beer shelf life over a period ofmonths This is accomplished by the development of tunnel pasteurization in whichthe beer bottle is subjected to 60C for 20 min Over-pasteurization which causesoxidation and can adversely affect beer flavor (38) is a potential physical hazardFurthermore it is crucial to check the time-temperature procedure with adequatecorrective actions for assuring the production of a satisfactory product
Bottle Inspection (CCP12)
Bottle inspection after the pasteurization step is important to ensure that bottleshave not been damaged during the process (39) Should such a situation occur theequipment has to be standardized by the production engineer
Labeling and Standardization (CCP13)
Labeling of the package should comply with the requirements of the CodexGeneral for the labeling of prepackaged foods (40) This means that the name of theproduct shall be clearly declared there must be a list of ingredients in descendingorder of proportion no other fruit may be represented pictorially except those usedand ldquothe date of minimum durabilityrdquo will be declared by the month and year inuncoded numerical sequence
BottleCan Packaging (CCP14)
Bottles (cans) are packaged into paperboard boxes of various sizes accordingto the bottle or can dimensions The encountered hazards can be of physical natureconcerning the bottles (cans) condition during the procedure
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 15
Storage (CCP15)
The finished beer undergoes chemical microbiological and organoleptic anal-ysis to ensure that its properties are within its specification range A synoptical pre-sentation of the occurring hazards CCPs CLs and preventive corrective measuresis given in Table 1
SAKE
Introduction
Sake is a fermented liquor made from rice and coming in many varietiesdepending on the raw materials manufacturing process and process after brewing(41) According to the earliest records sake was originally brewed from rice thathad been chewed to reach saccharification followed by natural fermentation Sakebrewed this way was used as a sacred wine in the worship of the Shinto gods Thisassociation with religion Shintoism and Buddhism has caused a deep intertwiningof sake with the traditions and social customs of Japan Thus today sake is servedat ceremonies and celebrations of all kinds (42) Sake has the highest alcoholpercentage by volume of any fermented beverage In its natural undiluted state itmay contain a potent 20 ethanol compared to 3ndash5 for beer or 9ndash12 for winewhich may reach higher values for fortified wines (4344) The central brewersrsquounion divides sake into four basic flavor types on four axes of sweet sour bitterand umai The latter is another translatorrsquos nightmare which generally ends uptranslated as delicious According to position established along these axes sakeis considered to be of ldquomature typerdquo ldquofragrant typerdquo ldquolight and smooth typerdquo orldquofull-bodied typerdquo (Fig 3) However no set of criteria can adequately express themultiplicity of sensations that together create the flavor unique to any individualsake but there is a perceived need for terms which quickly and simply give thegeneral idea
Figure 3 Main flavor types for sake characterization (43)
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16 KOURTIS AND ARVANITOYANNIS
Sake Main Production Stages
The main stages for sake production are schematically presented in Figure 4
Raw Materials (CCP1)
The main ingredients of Japanese sake are rice sake rice sake yeastand water The rice most suitable for sake should consist of large grains and shouldbe soft with a white part at its center due to coarse cell structure Rice should complywith the maximum residue limits for pesticides and insecticides established by theCodex Alimentarius Commission for this commodity (45) (CCP chemical hazard)For Japanese sake yellow koji mold (Aspergillus oryzae) is used Sake yeast (Sac-charomyces cerevisiae) is a microbe converting the occurring glucose and mineralsin rice and water into alcohol Employment of bubble-free type yeast eliminates
Figure 4 Process flow diagram of sake production (264647)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 17
the bubble removal step thus shortening the brewing period and reducing the costShould the factory wish to employ a specific yeast an adequate disinfection ofthe building interior is required otherwise undesirable bacteria may be introducedwhich could prove hazardous to human health (CCP microbiological hazard) (46)
Rice Polishing (CCP2)
The brown rice used for sake production must be first polished to remove theouter portion of the grain which contains fats proteins minerals and amino acidsthat can cause unpleasant flavors leaving the starch residues that are located in thecenter of the grain Nowadays machines are programmed to automatically removewhatever portion of the rice is required for the specific sake (47) The rice polishingratio (73ndash35) is expressed by the following formula (43)
Rice polishing ratio=(weight of white riceweight of brown rice)times100 (1)
The polishing process should be gently carried out because friction results inheat generation thereby greatly affecting water absorption and rice grain structureBroken grains are unlikely to satisfactorily ferment (47) Maybe the most importantstage in sake production consists of yeast starter mash production which can takeplace either with the classical Kimoto or slightly revised Yamahai process or withthe new ldquohigh speedrdquo methods (48)
Washing (CCP3)
After the rice has been polished rice powder clinging to the grain surface isremoved by washing Washing can be carried out either mechanically or manually(laborious hand washing) and should result in removing most of the organic andinorganic impurities reaching the CLs set by Codex Alimentarius of 15 and01 mm respectively
Soaking (Steeping)
Soaking allows rice to absorb the desired amount of water that is crucial toestablishing the rice consistency For sake produced ldquoen masserdquo simply dumpinginto a vat overnight for as long as 14 h is a usual case (47) However high polishedrice may be soaked within minutes In such a case an error of a minute might proveto have dire consequences for the end product (43)
Steaming (CCP4)
Steaming aims at softening the rice grains and breaking down the starchmolecules thus encouraging the growth of Aspergillus oryzae and eliminating all
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18 KOURTIS AND ARVANITOYANNIS
other microorganisms leaving an initially sterile environment prone to sake moldpropagation Presence of lactic acid bacteria (LAB) and yeasts may occur at theend of this step representing a microbiological hazard and resulting in consider-able organoleptic losses The time can vary from 20 to 60 min depending on thebrewer and apparatus employed (40ndash60 and 20 min for traditional and automatedrespectively) (4346)
Cooling
The ensuing division of steamed rice is mainly related to its further use Apart of it is directly cooled by air blower whereas 20ndash30 is transferred to a heatedculture room to be infected with bacteria spores (Aspergillus oryzae) for sake moldproduction
Koji
Since rice grains contain no sugar it is the action of koji mold that converts thestarch in the grains to sugar The steamed rice is first cooled to 15ndash36C before beingtransferred to the koji culture room (30C) Spores of the mold are sprinkled likefine dust on the rice when it has cooled down to 33C After the spores are kneadedinto the steamed rice the rice is heaped and wrapped in cloths to prevent heat andmoisture loss which are two crucial factors for satisfactory bacterial growth Tomaintain uniform temperature and moisture rice is spread and mixed twice the firsttime after 20 hours (upon the appearance of white flecks) and then 7ndash8 h thereafteraccompanied by a distinctive aroma release (48)
Main Mash (Moromi) and Fermentation (CCP5)
In fermentation the occurring chemical hazards are related to heavy metalspresence (As lt 02 Cd lt 001 Pb lt 03 mgL) pesticide residues (as mentionedin Codex Alimentarius) and residues of detergents (absence) and ethylene glycole(absence) Their CLs can be determined and monitored with specific chemicalanalyses The ingredients of main mash (water koji rice and steamed rice) areadded to the starter mash in three steps (moving from small to bigger recipient)over a period of 4 days at successively lower temperatures thus preventing thegrowth of airborne bacteria (Table 2) A day after the addition of all the ingredientsformation of a moist surface showing clear cracks occurs Furthermore the mashbegins to bubble (indication of fermentation progress) as gas is given off during theburgeoning fermentation The fermentation can take place at various temperaturesand its duration depends on it that is at lower temperatures it takes up to twoweeks but the sake aroma is much more appealing compared to that formed athigher temperatures The characteristic sake aroma results from combined flavor
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 19
Table 2 Quantities of Ingredients at Each Stage of Mixing the Main Mash (Moromi)
Yeast 1st 2nd 3rd 4thStarter (Moto) Addition Addition Addition Additiona Total
Total rice (kg) 210 470 850 1470 3000Steamed rice (kg) 140 330 650 1230 2350Koji rice (kg) 70 140 200 240 65030 Brewerrsquos 1200 1200
alcohol (L)Water (L) 230 420 1010 2030 360 405
aTraditional brewers mix the final mash in three stages The fourth addition of alcohol and wateris a controversial postwar development (Kondo 1984)
components of a number of compounds produced during fermentation (49) Theelevated alcohol content of the fermented sake is related to lipid metabolism ofyeast in the presence of proteolipid provided by the koji molds (5051)
Additions (CCP6)
The addition of alcohol at this stage is carried out unless it is clearly statedthat sake does not contain any alcohol from extraneous sources The added alcoholshould not contain methanol or if it does the content of the latter should be lessthan 05 gL because of its toxicity (CCP chemical hazard)
Pressing
Automatic machine presses (consisting of a series of panels with balloon-likesacks attached) are most widely used nowadays instead of the traditional time-consuming method using long bags The remained caked lees are employed forpickle production and cooking or sedimentation of rice particles may occur Alter-natively sedimentation of rice particles at the bottom of the tank may take place
Filtration
Coloring and aging (maturation) inhibition can be effected by using activatedcharcoal filters
Pasteurization (CCP7 and CCP8)
Heating sake preferably twice at 65C kills off the remaining yeast stops en-zyme action and deactivates the lactic acid bacteria that will eventually spoil sakeThis process represents a microbiological hazard for which the specific plant may
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ORDER REPRINTS
20 KOURTIS AND ARVANITOYANNIS
set CLs However in recent years refrigerated storage and transport have madeunpasteurized sake with characteristic aroma available to the consumer (43)
Dilution
The produced sake in its raw state (Genchu) contains more than 20 alcoholby volume but it is generally diluted to about 15ndash16 vol-
BottlingStorageDistribution
The applied procedures are similar to those mentioned for the beer productionA summary of the occurring hazards CCPs CLs and preventive and correc-
tive measures is given in Table 3
WINE
Introduction
Wines are made from the fruit of Vitis vinifera of which there are a greatnumber of varieties growing in many parts of the world The history of wine isinextricably interwoven with human history It might be as true to say that it waswith wine that civilization began for the vine takes longer to mature than any othercrop and does not produce grapes for wine making until its fourth year It is notexactly known when men first had wine but it was accepted as a gift from the godsthe Egyptians attributed it to Osiris and the Greeks to Dionysos Mesopotamia andthe Caucasian slopes were no doubt early sources of wine from where it was spreadto Egypt and Greece and then to the rest of the world (52)
Wine Main Production Stages
The main stages for wine production are schematically presented in Figure 5
Harvesting (CCP1)
Grape harvesting is a CCP comprising both physical and chemical hazardsPhysically the grapes should be sound without rotten parts otherwise oxidativeand microbial contamination can rapidly develop Therefore harvesting shouldbe conducted with the greatest possible care and an efficient disease managementsystem should be applied (5354) Pesticides play an important role in pest man-agement but they should be handled with care because they constitute chemicalhazards (55) At the time of harvest the grapes must have also reached the correctmaturity when Brix and Total Acidity (TA) levels indicate maturity of wine Sincepesticide and fungicide residues on the surface of the berries constitute chemical
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 21
hazards Oliva et al (56) proposed a rapid and simple gas chromatographic methodfor their determination The maximum residue limits for pesticides in grapes andwines are provided by Codex Alimentarius (45) and Organisation International duVin (57) Finally the bulk bins used for grapes transportation should be effectivelydecontaminated to avoid any microbial infection
Stemming
Stemming includes the removal of stem leaves and grape stalks before crush-ing This procedure has several advantages because the total volume of processedproduct drops by 30 thus resulting in smaller tanks and eventually increasingthe productrsquos alcoholic content (58) However the end of fermentation and the al-cohol content of finished product depend mostly on the Brix level of initial grapesStemmers usually contain a perforated cylinder allowing berries to pass throughbut prevent the passage of stems stalks and leaves
Crushing
Crushing typically immediately follows stemming since some crushing ofthe fruit occurs during stemming The released juice is highly susceptible to oxida-tive browning and microbial contamination The most common crushing processesinvolve pressing the fruit against a perforated wall or passing the fruit through a setof rollers It is very important to avoid crushing the seeds to preclude contaminat-ing the must with seed oils the oxidation of which could produce rancid odors andconstitute an undesirable source of bitter tannins Equally important is the properhandling of product because inappropriate timing might lead to a sudden startof alcoholic fermentation and consequently to higher fermentation temperatureswhile a delay might cause microbial contamination and oxidative browning (59)
Maceration
Maceration is the breakdown of grape solids after crushing of grapes Whilemaceration is always involved in the initial stage of red wine fermentation the long-standing trend has been to limit maceration in white wine production Temperatureand duration of maceration depend on grape and wine variety Usually for white androse wines the maceration time is less than 24 h red destined for early consumptionis macerated for 3ndash5 days and red for aging is macerated from 5 days to 3 weeksFermentation usually occurs during this or at the end of maceration The amount ofthe antimicrobial to be used usually added to white musts that are most sensitive tooxidation depends on the crop health and maceration temperature Sulfur dioxidehas a distinct advantage over other antimicrobial agents because of the relativeinsensitivity of the wine yeasts to its action However it is also toxic or inhibitoryto most bacteria and yeasts (ie Candida Pichia Hansenula) at low concentrations(60) and has a rather low retention capability after the clarification step (61)
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22 KOURTIS AND ARVANITOYANNISTa
ble
3Su
mm
ary
ofH
azar
dsC
CPs
CL
sM
onito
ring
Cor
rect
ive
Act
ions
and
Pers
onne
lRes
pons
ible
for
Sake
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
a(M
CP
)bM
easu
res
CC
PPa
ram
eter
(CL
s)Pr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
CC
ertifi
edsu
pplie
rs
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
wat
er
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Cer
tified
supp
liers
Hea
vym
etal
spr
esen
cein
wat
er
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Eva
luat
ion
ofth
ede
cont
amin
atin
gm
etho
ds
MC
ertifi
edsu
pplie
rs
prop
erpr
epar
atio
n
Mic
robi
alco
ntam
inat
ion
ofth
ecu
lture
100
clea
nM
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Wat
erm
icro
biol
ogic
alqu
ality
Abs
ence
ofpa
thog
ens
Insp
ectio
nof
the
equi
pmen
t
Ric
epo
lishi
ng(C
CP2
)C
Cer
tified
supp
lier
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
polis
hed
rice
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Was
hing
(CC
P3)
PC
ertifi
edsu
pplie
rs
inst
alla
tion
ofau
tom
atic
sepa
rato
r
Ani
mal
impu
ritie
sO
ther
orga
nic
and
inor
gani
cm
ater
01
mm
15
mm
01
mm
Spec
ific
exam
inat
ion
Rew
ashi
ngof
spec
ific
batc
hch
ange
supp
lier
Qua
lity
cont
rol
man
ager
Stea
min
g(f
orun
past
euri
sed
sake
)(C
CP4
)
MG
MP
sche
dule
dm
icro
biol
ogic
alco
ntro
ls
Pres
ence
ofye
asts
and
LA
B
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Spec
ific
batc
hre
proc
essi
ng
CIP
stan
dar-
disa
tion
Qua
lity
cont
rol
man
ager
T
rain
ned
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 23
Ferm
enta
tion
(CC
P5)
CM
ater
ialc
ontr
ol
GM
Pco
rros
ion
chec
ks
Hea
vym
etal
pres
ence
Pest
icid
ere
sidu
es
Aslt
02
Cd
lt
001
Pb
lt
03
(mg
L)
Spec
ific
chem
ical
anal
ysis
Dem
etal
lisat
ion
Cha
nge
supp
lier
Rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
GM
Pus
eof
nont
oxic
glyc
ole
Res
idue
sof
ehty
lene
glyc
ole
ampde
terg
ents
0Sp
ecifi
cch
emic
alan
alys
isD
ilutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Alc
ohol
addi
tion
(CC
P6)
CC
ertifi
edsu
pplie
rM
etha
nolc
onte
ntlt
05
gL
GC
exam
inat
ion
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erPa
steu
riza
tion
(CC
P7amp
CC
P8)
MR
unni
ngof
past
euri
ser
acco
rdin
gto
prog
ram
Det
ectio
nof
yeas
tsL
AB
en
zym
atic
activ
ity
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Tem
pera
ture
adju
stm
ent
batc
hre
proc
essi
ng
prop
erm
achi
nery
disi
nfec
tion
Qua
lity
cont
rol
man
ager
Tech
nica
lm
anag
er
aR
egar
ding
the
proc
edur
esof
bottl
ing
stor
age
and
dist
ribu
tion
the
CC
Psar
esi
mila
rto
thos
em
entio
ned
inTa
ble
1fo
rbe
erpr
oduc
tion
bM
CP
stan
dfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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26 KOURTIS AND ARVANITOYANNIS
Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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ORDER REPRINTS
28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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ORDER REPRINTS
34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
by [
Sule
yman
Dem
irel
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vers
itesi
] at
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ber
2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
nloa
ded
by [
Sule
yman
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irel
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vers
itesi
] at
09
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ber
2011
ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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irel
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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ded
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yman
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irel
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itesi
] at
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2011
ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
Dow
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ded
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yman
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irel
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itesi
] at
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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ded
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ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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ded
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yman
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irel
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itesi
] at
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ber
2011
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 13
drops from 52 to 42 and by its completion the yeast is removed either as a top orbottom crop and retained to pitch the next fermentation Apart from the conventionalmicrobial detection methods with plate count several rapid detection methodspotentially applied in breweries such as ATP bioluminescence flow cytometryand polymerase chain reaction have been developed to reduce the incubation timefrom 3ndash4 days to 1ndash2 (2930)
Maturation
Maturation includes all those changes occurring between the end of primaryfermentation to beer filtration (31) Ale is matured at relatively warm temperatures12ndash20C while lagers are held under much cooler conditions The warmer temper-atures allow the rapid metabolism of any residual and priming sugars as well asloss of green flavors within 1ndash2 weeks depending on beer type yeast strain wortcomposition and primary fermentation conditions In case of lager the beer used tobe held at refrigerated temperatures for up to several months after fermentation al-lowing formation of proteintannin complexes (18) Today the enzyme addition hassubstantially shortened this process to several weeks during which flavor maturesEnzymes such as papain may be added during transfer between fermentation andmaturation tank The dosage of the proteolytic enzyme varies depending on typeof beer and process Enzyme activity decreases progressively during maturationuntil its inactivation with pasteurization Part of the enzyme absorbed in the yeastsurface is removed during filtration (19)
Filtration (CCP7)
Beer produced during fermentation is turbid and should be clarified prior to itsmarketing This turbidity is due to the presence of yeasts and proteinaceous materi-als associated with carbohydrates and polyphenols The formation of these proteinprecipitates is attributed to cold temperature low pH and poor solubility in alcoholicsolutions (32) To prevent this from occurring in the final product the beer may besubjected to various chill-proofing treatments during its storage These treatmentsgenerally include the addition of clays to absorb the colloidal materials or prote-olytic enzymes used to further solubilize the protein fraction (33) Since oxygenuptake during this process could severely affect the product organoleptic charac-teristics a CCP of dissolved oxygen should be applied with a CL of 02 ppm (34)
Packaging and Sealing
The packing section comprises several CCPs including the containers to beused their cleaning and disinfection (CCP8) the filler line (CCP9) and the sealer(CCP10) The bursting pressure of the bottles as guaranteed by the manufacturerin his specifications for the new glass may no longer be valid in case of reusable
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14 KOURTIS AND ARVANITOYANNIS
bottles due to the considerable physical stress during already exerted upon themduring the filling process Insufficient cleaning of reusable bottles due to low temper-atures and concentrations of the employed cleaning solutions as well as presence ofextraneous entrapped materials within bottles and improper emptying consist pos-sible hazards Moreover cleaning solution remnants and shards introduced throughthe procedure pose problems under working conditions The beer filler may be con-taminated by cleaning and disinfection solutions Contamination sources may bedue to inadequate pressure or faulty CIP system resulting in cleaning and disinfect-ing solution remains in the pressure tank or the ring bowl of the filler (3536) Thecrown corker should be correctly installed the filling pressure of bottle caps on themouths of the bottles should be adjusted to ensure a specified blow-off effect toavoid bottle bursting After filling there should be a full bottle inspector detectingglass particles in bottles or possible leakage (37)
Bottle Pasteurization (CCP11)
Pasteurization is carried out to ensure the beer shelf life over a period ofmonths This is accomplished by the development of tunnel pasteurization in whichthe beer bottle is subjected to 60C for 20 min Over-pasteurization which causesoxidation and can adversely affect beer flavor (38) is a potential physical hazardFurthermore it is crucial to check the time-temperature procedure with adequatecorrective actions for assuring the production of a satisfactory product
Bottle Inspection (CCP12)
Bottle inspection after the pasteurization step is important to ensure that bottleshave not been damaged during the process (39) Should such a situation occur theequipment has to be standardized by the production engineer
Labeling and Standardization (CCP13)
Labeling of the package should comply with the requirements of the CodexGeneral for the labeling of prepackaged foods (40) This means that the name of theproduct shall be clearly declared there must be a list of ingredients in descendingorder of proportion no other fruit may be represented pictorially except those usedand ldquothe date of minimum durabilityrdquo will be declared by the month and year inuncoded numerical sequence
BottleCan Packaging (CCP14)
Bottles (cans) are packaged into paperboard boxes of various sizes accordingto the bottle or can dimensions The encountered hazards can be of physical natureconcerning the bottles (cans) condition during the procedure
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 15
Storage (CCP15)
The finished beer undergoes chemical microbiological and organoleptic anal-ysis to ensure that its properties are within its specification range A synoptical pre-sentation of the occurring hazards CCPs CLs and preventive corrective measuresis given in Table 1
SAKE
Introduction
Sake is a fermented liquor made from rice and coming in many varietiesdepending on the raw materials manufacturing process and process after brewing(41) According to the earliest records sake was originally brewed from rice thathad been chewed to reach saccharification followed by natural fermentation Sakebrewed this way was used as a sacred wine in the worship of the Shinto gods Thisassociation with religion Shintoism and Buddhism has caused a deep intertwiningof sake with the traditions and social customs of Japan Thus today sake is servedat ceremonies and celebrations of all kinds (42) Sake has the highest alcoholpercentage by volume of any fermented beverage In its natural undiluted state itmay contain a potent 20 ethanol compared to 3ndash5 for beer or 9ndash12 for winewhich may reach higher values for fortified wines (4344) The central brewersrsquounion divides sake into four basic flavor types on four axes of sweet sour bitterand umai The latter is another translatorrsquos nightmare which generally ends uptranslated as delicious According to position established along these axes sakeis considered to be of ldquomature typerdquo ldquofragrant typerdquo ldquolight and smooth typerdquo orldquofull-bodied typerdquo (Fig 3) However no set of criteria can adequately express themultiplicity of sensations that together create the flavor unique to any individualsake but there is a perceived need for terms which quickly and simply give thegeneral idea
Figure 3 Main flavor types for sake characterization (43)
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16 KOURTIS AND ARVANITOYANNIS
Sake Main Production Stages
The main stages for sake production are schematically presented in Figure 4
Raw Materials (CCP1)
The main ingredients of Japanese sake are rice sake rice sake yeastand water The rice most suitable for sake should consist of large grains and shouldbe soft with a white part at its center due to coarse cell structure Rice should complywith the maximum residue limits for pesticides and insecticides established by theCodex Alimentarius Commission for this commodity (45) (CCP chemical hazard)For Japanese sake yellow koji mold (Aspergillus oryzae) is used Sake yeast (Sac-charomyces cerevisiae) is a microbe converting the occurring glucose and mineralsin rice and water into alcohol Employment of bubble-free type yeast eliminates
Figure 4 Process flow diagram of sake production (264647)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 17
the bubble removal step thus shortening the brewing period and reducing the costShould the factory wish to employ a specific yeast an adequate disinfection ofthe building interior is required otherwise undesirable bacteria may be introducedwhich could prove hazardous to human health (CCP microbiological hazard) (46)
Rice Polishing (CCP2)
The brown rice used for sake production must be first polished to remove theouter portion of the grain which contains fats proteins minerals and amino acidsthat can cause unpleasant flavors leaving the starch residues that are located in thecenter of the grain Nowadays machines are programmed to automatically removewhatever portion of the rice is required for the specific sake (47) The rice polishingratio (73ndash35) is expressed by the following formula (43)
Rice polishing ratio=(weight of white riceweight of brown rice)times100 (1)
The polishing process should be gently carried out because friction results inheat generation thereby greatly affecting water absorption and rice grain structureBroken grains are unlikely to satisfactorily ferment (47) Maybe the most importantstage in sake production consists of yeast starter mash production which can takeplace either with the classical Kimoto or slightly revised Yamahai process or withthe new ldquohigh speedrdquo methods (48)
Washing (CCP3)
After the rice has been polished rice powder clinging to the grain surface isremoved by washing Washing can be carried out either mechanically or manually(laborious hand washing) and should result in removing most of the organic andinorganic impurities reaching the CLs set by Codex Alimentarius of 15 and01 mm respectively
Soaking (Steeping)
Soaking allows rice to absorb the desired amount of water that is crucial toestablishing the rice consistency For sake produced ldquoen masserdquo simply dumpinginto a vat overnight for as long as 14 h is a usual case (47) However high polishedrice may be soaked within minutes In such a case an error of a minute might proveto have dire consequences for the end product (43)
Steaming (CCP4)
Steaming aims at softening the rice grains and breaking down the starchmolecules thus encouraging the growth of Aspergillus oryzae and eliminating all
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18 KOURTIS AND ARVANITOYANNIS
other microorganisms leaving an initially sterile environment prone to sake moldpropagation Presence of lactic acid bacteria (LAB) and yeasts may occur at theend of this step representing a microbiological hazard and resulting in consider-able organoleptic losses The time can vary from 20 to 60 min depending on thebrewer and apparatus employed (40ndash60 and 20 min for traditional and automatedrespectively) (4346)
Cooling
The ensuing division of steamed rice is mainly related to its further use Apart of it is directly cooled by air blower whereas 20ndash30 is transferred to a heatedculture room to be infected with bacteria spores (Aspergillus oryzae) for sake moldproduction
Koji
Since rice grains contain no sugar it is the action of koji mold that converts thestarch in the grains to sugar The steamed rice is first cooled to 15ndash36C before beingtransferred to the koji culture room (30C) Spores of the mold are sprinkled likefine dust on the rice when it has cooled down to 33C After the spores are kneadedinto the steamed rice the rice is heaped and wrapped in cloths to prevent heat andmoisture loss which are two crucial factors for satisfactory bacterial growth Tomaintain uniform temperature and moisture rice is spread and mixed twice the firsttime after 20 hours (upon the appearance of white flecks) and then 7ndash8 h thereafteraccompanied by a distinctive aroma release (48)
Main Mash (Moromi) and Fermentation (CCP5)
In fermentation the occurring chemical hazards are related to heavy metalspresence (As lt 02 Cd lt 001 Pb lt 03 mgL) pesticide residues (as mentionedin Codex Alimentarius) and residues of detergents (absence) and ethylene glycole(absence) Their CLs can be determined and monitored with specific chemicalanalyses The ingredients of main mash (water koji rice and steamed rice) areadded to the starter mash in three steps (moving from small to bigger recipient)over a period of 4 days at successively lower temperatures thus preventing thegrowth of airborne bacteria (Table 2) A day after the addition of all the ingredientsformation of a moist surface showing clear cracks occurs Furthermore the mashbegins to bubble (indication of fermentation progress) as gas is given off during theburgeoning fermentation The fermentation can take place at various temperaturesand its duration depends on it that is at lower temperatures it takes up to twoweeks but the sake aroma is much more appealing compared to that formed athigher temperatures The characteristic sake aroma results from combined flavor
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 19
Table 2 Quantities of Ingredients at Each Stage of Mixing the Main Mash (Moromi)
Yeast 1st 2nd 3rd 4thStarter (Moto) Addition Addition Addition Additiona Total
Total rice (kg) 210 470 850 1470 3000Steamed rice (kg) 140 330 650 1230 2350Koji rice (kg) 70 140 200 240 65030 Brewerrsquos 1200 1200
alcohol (L)Water (L) 230 420 1010 2030 360 405
aTraditional brewers mix the final mash in three stages The fourth addition of alcohol and wateris a controversial postwar development (Kondo 1984)
components of a number of compounds produced during fermentation (49) Theelevated alcohol content of the fermented sake is related to lipid metabolism ofyeast in the presence of proteolipid provided by the koji molds (5051)
Additions (CCP6)
The addition of alcohol at this stage is carried out unless it is clearly statedthat sake does not contain any alcohol from extraneous sources The added alcoholshould not contain methanol or if it does the content of the latter should be lessthan 05 gL because of its toxicity (CCP chemical hazard)
Pressing
Automatic machine presses (consisting of a series of panels with balloon-likesacks attached) are most widely used nowadays instead of the traditional time-consuming method using long bags The remained caked lees are employed forpickle production and cooking or sedimentation of rice particles may occur Alter-natively sedimentation of rice particles at the bottom of the tank may take place
Filtration
Coloring and aging (maturation) inhibition can be effected by using activatedcharcoal filters
Pasteurization (CCP7 and CCP8)
Heating sake preferably twice at 65C kills off the remaining yeast stops en-zyme action and deactivates the lactic acid bacteria that will eventually spoil sakeThis process represents a microbiological hazard for which the specific plant may
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20 KOURTIS AND ARVANITOYANNIS
set CLs However in recent years refrigerated storage and transport have madeunpasteurized sake with characteristic aroma available to the consumer (43)
Dilution
The produced sake in its raw state (Genchu) contains more than 20 alcoholby volume but it is generally diluted to about 15ndash16 vol-
BottlingStorageDistribution
The applied procedures are similar to those mentioned for the beer productionA summary of the occurring hazards CCPs CLs and preventive and correc-
tive measures is given in Table 3
WINE
Introduction
Wines are made from the fruit of Vitis vinifera of which there are a greatnumber of varieties growing in many parts of the world The history of wine isinextricably interwoven with human history It might be as true to say that it waswith wine that civilization began for the vine takes longer to mature than any othercrop and does not produce grapes for wine making until its fourth year It is notexactly known when men first had wine but it was accepted as a gift from the godsthe Egyptians attributed it to Osiris and the Greeks to Dionysos Mesopotamia andthe Caucasian slopes were no doubt early sources of wine from where it was spreadto Egypt and Greece and then to the rest of the world (52)
Wine Main Production Stages
The main stages for wine production are schematically presented in Figure 5
Harvesting (CCP1)
Grape harvesting is a CCP comprising both physical and chemical hazardsPhysically the grapes should be sound without rotten parts otherwise oxidativeand microbial contamination can rapidly develop Therefore harvesting shouldbe conducted with the greatest possible care and an efficient disease managementsystem should be applied (5354) Pesticides play an important role in pest man-agement but they should be handled with care because they constitute chemicalhazards (55) At the time of harvest the grapes must have also reached the correctmaturity when Brix and Total Acidity (TA) levels indicate maturity of wine Sincepesticide and fungicide residues on the surface of the berries constitute chemical
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 21
hazards Oliva et al (56) proposed a rapid and simple gas chromatographic methodfor their determination The maximum residue limits for pesticides in grapes andwines are provided by Codex Alimentarius (45) and Organisation International duVin (57) Finally the bulk bins used for grapes transportation should be effectivelydecontaminated to avoid any microbial infection
Stemming
Stemming includes the removal of stem leaves and grape stalks before crush-ing This procedure has several advantages because the total volume of processedproduct drops by 30 thus resulting in smaller tanks and eventually increasingthe productrsquos alcoholic content (58) However the end of fermentation and the al-cohol content of finished product depend mostly on the Brix level of initial grapesStemmers usually contain a perforated cylinder allowing berries to pass throughbut prevent the passage of stems stalks and leaves
Crushing
Crushing typically immediately follows stemming since some crushing ofthe fruit occurs during stemming The released juice is highly susceptible to oxida-tive browning and microbial contamination The most common crushing processesinvolve pressing the fruit against a perforated wall or passing the fruit through a setof rollers It is very important to avoid crushing the seeds to preclude contaminat-ing the must with seed oils the oxidation of which could produce rancid odors andconstitute an undesirable source of bitter tannins Equally important is the properhandling of product because inappropriate timing might lead to a sudden startof alcoholic fermentation and consequently to higher fermentation temperatureswhile a delay might cause microbial contamination and oxidative browning (59)
Maceration
Maceration is the breakdown of grape solids after crushing of grapes Whilemaceration is always involved in the initial stage of red wine fermentation the long-standing trend has been to limit maceration in white wine production Temperatureand duration of maceration depend on grape and wine variety Usually for white androse wines the maceration time is less than 24 h red destined for early consumptionis macerated for 3ndash5 days and red for aging is macerated from 5 days to 3 weeksFermentation usually occurs during this or at the end of maceration The amount ofthe antimicrobial to be used usually added to white musts that are most sensitive tooxidation depends on the crop health and maceration temperature Sulfur dioxidehas a distinct advantage over other antimicrobial agents because of the relativeinsensitivity of the wine yeasts to its action However it is also toxic or inhibitoryto most bacteria and yeasts (ie Candida Pichia Hansenula) at low concentrations(60) and has a rather low retention capability after the clarification step (61)
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22 KOURTIS AND ARVANITOYANNISTa
ble
3Su
mm
ary
ofH
azar
dsC
CPs
CL
sM
onito
ring
Cor
rect
ive
Act
ions
and
Pers
onne
lRes
pons
ible
for
Sake
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
a(M
CP
)bM
easu
res
CC
PPa
ram
eter
(CL
s)Pr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
CC
ertifi
edsu
pplie
rs
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
wat
er
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Cer
tified
supp
liers
Hea
vym
etal
spr
esen
cein
wat
er
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Eva
luat
ion
ofth
ede
cont
amin
atin
gm
etho
ds
MC
ertifi
edsu
pplie
rs
prop
erpr
epar
atio
n
Mic
robi
alco
ntam
inat
ion
ofth
ecu
lture
100
clea
nM
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Wat
erm
icro
biol
ogic
alqu
ality
Abs
ence
ofpa
thog
ens
Insp
ectio
nof
the
equi
pmen
t
Ric
epo
lishi
ng(C
CP2
)C
Cer
tified
supp
lier
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
polis
hed
rice
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Was
hing
(CC
P3)
PC
ertifi
edsu
pplie
rs
inst
alla
tion
ofau
tom
atic
sepa
rato
r
Ani
mal
impu
ritie
sO
ther
orga
nic
and
inor
gani
cm
ater
01
mm
15
mm
01
mm
Spec
ific
exam
inat
ion
Rew
ashi
ngof
spec
ific
batc
hch
ange
supp
lier
Qua
lity
cont
rol
man
ager
Stea
min
g(f
orun
past
euri
sed
sake
)(C
CP4
)
MG
MP
sche
dule
dm
icro
biol
ogic
alco
ntro
ls
Pres
ence
ofye
asts
and
LA
B
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Spec
ific
batc
hre
proc
essi
ng
CIP
stan
dar-
disa
tion
Qua
lity
cont
rol
man
ager
T
rain
ned
pers
onne
l
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 23
Ferm
enta
tion
(CC
P5)
CM
ater
ialc
ontr
ol
GM
Pco
rros
ion
chec
ks
Hea
vym
etal
pres
ence
Pest
icid
ere
sidu
es
Aslt
02
Cd
lt
001
Pb
lt
03
(mg
L)
Spec
ific
chem
ical
anal
ysis
Dem
etal
lisat
ion
Cha
nge
supp
lier
Rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
GM
Pus
eof
nont
oxic
glyc
ole
Res
idue
sof
ehty
lene
glyc
ole
ampde
terg
ents
0Sp
ecifi
cch
emic
alan
alys
isD
ilutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Alc
ohol
addi
tion
(CC
P6)
CC
ertifi
edsu
pplie
rM
etha
nolc
onte
ntlt
05
gL
GC
exam
inat
ion
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erPa
steu
riza
tion
(CC
P7amp
CC
P8)
MR
unni
ngof
past
euri
ser
acco
rdin
gto
prog
ram
Det
ectio
nof
yeas
tsL
AB
en
zym
atic
activ
ity
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Tem
pera
ture
adju
stm
ent
batc
hre
proc
essi
ng
prop
erm
achi
nery
disi
nfec
tion
Qua
lity
cont
rol
man
ager
Tech
nica
lm
anag
er
aR
egar
ding
the
proc
edur
esof
bottl
ing
stor
age
and
dist
ribu
tion
the
CC
Psar
esi
mila
rto
thos
em
entio
ned
inTa
ble
1fo
rbe
erpr
oduc
tion
bM
CP
stan
dfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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26 KOURTIS AND ARVANITOYANNIS
Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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ORDER REPRINTS
28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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ORDER REPRINTS
34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
by [
Sule
yman
Dem
irel
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vers
itesi
] at
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ber
2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
nloa
ded
by [
Sule
yman
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irel
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vers
itesi
] at
09
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ber
2011
ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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irel
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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ded
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yman
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irel
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itesi
] at
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2011
ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
Dow
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ded
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yman
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irel
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itesi
] at
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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ded
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ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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ded
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yman
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irel
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itesi
] at
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ber
2011
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14 KOURTIS AND ARVANITOYANNIS
bottles due to the considerable physical stress during already exerted upon themduring the filling process Insufficient cleaning of reusable bottles due to low temper-atures and concentrations of the employed cleaning solutions as well as presence ofextraneous entrapped materials within bottles and improper emptying consist pos-sible hazards Moreover cleaning solution remnants and shards introduced throughthe procedure pose problems under working conditions The beer filler may be con-taminated by cleaning and disinfection solutions Contamination sources may bedue to inadequate pressure or faulty CIP system resulting in cleaning and disinfect-ing solution remains in the pressure tank or the ring bowl of the filler (3536) Thecrown corker should be correctly installed the filling pressure of bottle caps on themouths of the bottles should be adjusted to ensure a specified blow-off effect toavoid bottle bursting After filling there should be a full bottle inspector detectingglass particles in bottles or possible leakage (37)
Bottle Pasteurization (CCP11)
Pasteurization is carried out to ensure the beer shelf life over a period ofmonths This is accomplished by the development of tunnel pasteurization in whichthe beer bottle is subjected to 60C for 20 min Over-pasteurization which causesoxidation and can adversely affect beer flavor (38) is a potential physical hazardFurthermore it is crucial to check the time-temperature procedure with adequatecorrective actions for assuring the production of a satisfactory product
Bottle Inspection (CCP12)
Bottle inspection after the pasteurization step is important to ensure that bottleshave not been damaged during the process (39) Should such a situation occur theequipment has to be standardized by the production engineer
Labeling and Standardization (CCP13)
Labeling of the package should comply with the requirements of the CodexGeneral for the labeling of prepackaged foods (40) This means that the name of theproduct shall be clearly declared there must be a list of ingredients in descendingorder of proportion no other fruit may be represented pictorially except those usedand ldquothe date of minimum durabilityrdquo will be declared by the month and year inuncoded numerical sequence
BottleCan Packaging (CCP14)
Bottles (cans) are packaged into paperboard boxes of various sizes accordingto the bottle or can dimensions The encountered hazards can be of physical natureconcerning the bottles (cans) condition during the procedure
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 15
Storage (CCP15)
The finished beer undergoes chemical microbiological and organoleptic anal-ysis to ensure that its properties are within its specification range A synoptical pre-sentation of the occurring hazards CCPs CLs and preventive corrective measuresis given in Table 1
SAKE
Introduction
Sake is a fermented liquor made from rice and coming in many varietiesdepending on the raw materials manufacturing process and process after brewing(41) According to the earliest records sake was originally brewed from rice thathad been chewed to reach saccharification followed by natural fermentation Sakebrewed this way was used as a sacred wine in the worship of the Shinto gods Thisassociation with religion Shintoism and Buddhism has caused a deep intertwiningof sake with the traditions and social customs of Japan Thus today sake is servedat ceremonies and celebrations of all kinds (42) Sake has the highest alcoholpercentage by volume of any fermented beverage In its natural undiluted state itmay contain a potent 20 ethanol compared to 3ndash5 for beer or 9ndash12 for winewhich may reach higher values for fortified wines (4344) The central brewersrsquounion divides sake into four basic flavor types on four axes of sweet sour bitterand umai The latter is another translatorrsquos nightmare which generally ends uptranslated as delicious According to position established along these axes sakeis considered to be of ldquomature typerdquo ldquofragrant typerdquo ldquolight and smooth typerdquo orldquofull-bodied typerdquo (Fig 3) However no set of criteria can adequately express themultiplicity of sensations that together create the flavor unique to any individualsake but there is a perceived need for terms which quickly and simply give thegeneral idea
Figure 3 Main flavor types for sake characterization (43)
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16 KOURTIS AND ARVANITOYANNIS
Sake Main Production Stages
The main stages for sake production are schematically presented in Figure 4
Raw Materials (CCP1)
The main ingredients of Japanese sake are rice sake rice sake yeastand water The rice most suitable for sake should consist of large grains and shouldbe soft with a white part at its center due to coarse cell structure Rice should complywith the maximum residue limits for pesticides and insecticides established by theCodex Alimentarius Commission for this commodity (45) (CCP chemical hazard)For Japanese sake yellow koji mold (Aspergillus oryzae) is used Sake yeast (Sac-charomyces cerevisiae) is a microbe converting the occurring glucose and mineralsin rice and water into alcohol Employment of bubble-free type yeast eliminates
Figure 4 Process flow diagram of sake production (264647)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 17
the bubble removal step thus shortening the brewing period and reducing the costShould the factory wish to employ a specific yeast an adequate disinfection ofthe building interior is required otherwise undesirable bacteria may be introducedwhich could prove hazardous to human health (CCP microbiological hazard) (46)
Rice Polishing (CCP2)
The brown rice used for sake production must be first polished to remove theouter portion of the grain which contains fats proteins minerals and amino acidsthat can cause unpleasant flavors leaving the starch residues that are located in thecenter of the grain Nowadays machines are programmed to automatically removewhatever portion of the rice is required for the specific sake (47) The rice polishingratio (73ndash35) is expressed by the following formula (43)
Rice polishing ratio=(weight of white riceweight of brown rice)times100 (1)
The polishing process should be gently carried out because friction results inheat generation thereby greatly affecting water absorption and rice grain structureBroken grains are unlikely to satisfactorily ferment (47) Maybe the most importantstage in sake production consists of yeast starter mash production which can takeplace either with the classical Kimoto or slightly revised Yamahai process or withthe new ldquohigh speedrdquo methods (48)
Washing (CCP3)
After the rice has been polished rice powder clinging to the grain surface isremoved by washing Washing can be carried out either mechanically or manually(laborious hand washing) and should result in removing most of the organic andinorganic impurities reaching the CLs set by Codex Alimentarius of 15 and01 mm respectively
Soaking (Steeping)
Soaking allows rice to absorb the desired amount of water that is crucial toestablishing the rice consistency For sake produced ldquoen masserdquo simply dumpinginto a vat overnight for as long as 14 h is a usual case (47) However high polishedrice may be soaked within minutes In such a case an error of a minute might proveto have dire consequences for the end product (43)
Steaming (CCP4)
Steaming aims at softening the rice grains and breaking down the starchmolecules thus encouraging the growth of Aspergillus oryzae and eliminating all
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18 KOURTIS AND ARVANITOYANNIS
other microorganisms leaving an initially sterile environment prone to sake moldpropagation Presence of lactic acid bacteria (LAB) and yeasts may occur at theend of this step representing a microbiological hazard and resulting in consider-able organoleptic losses The time can vary from 20 to 60 min depending on thebrewer and apparatus employed (40ndash60 and 20 min for traditional and automatedrespectively) (4346)
Cooling
The ensuing division of steamed rice is mainly related to its further use Apart of it is directly cooled by air blower whereas 20ndash30 is transferred to a heatedculture room to be infected with bacteria spores (Aspergillus oryzae) for sake moldproduction
Koji
Since rice grains contain no sugar it is the action of koji mold that converts thestarch in the grains to sugar The steamed rice is first cooled to 15ndash36C before beingtransferred to the koji culture room (30C) Spores of the mold are sprinkled likefine dust on the rice when it has cooled down to 33C After the spores are kneadedinto the steamed rice the rice is heaped and wrapped in cloths to prevent heat andmoisture loss which are two crucial factors for satisfactory bacterial growth Tomaintain uniform temperature and moisture rice is spread and mixed twice the firsttime after 20 hours (upon the appearance of white flecks) and then 7ndash8 h thereafteraccompanied by a distinctive aroma release (48)
Main Mash (Moromi) and Fermentation (CCP5)
In fermentation the occurring chemical hazards are related to heavy metalspresence (As lt 02 Cd lt 001 Pb lt 03 mgL) pesticide residues (as mentionedin Codex Alimentarius) and residues of detergents (absence) and ethylene glycole(absence) Their CLs can be determined and monitored with specific chemicalanalyses The ingredients of main mash (water koji rice and steamed rice) areadded to the starter mash in three steps (moving from small to bigger recipient)over a period of 4 days at successively lower temperatures thus preventing thegrowth of airborne bacteria (Table 2) A day after the addition of all the ingredientsformation of a moist surface showing clear cracks occurs Furthermore the mashbegins to bubble (indication of fermentation progress) as gas is given off during theburgeoning fermentation The fermentation can take place at various temperaturesand its duration depends on it that is at lower temperatures it takes up to twoweeks but the sake aroma is much more appealing compared to that formed athigher temperatures The characteristic sake aroma results from combined flavor
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 19
Table 2 Quantities of Ingredients at Each Stage of Mixing the Main Mash (Moromi)
Yeast 1st 2nd 3rd 4thStarter (Moto) Addition Addition Addition Additiona Total
Total rice (kg) 210 470 850 1470 3000Steamed rice (kg) 140 330 650 1230 2350Koji rice (kg) 70 140 200 240 65030 Brewerrsquos 1200 1200
alcohol (L)Water (L) 230 420 1010 2030 360 405
aTraditional brewers mix the final mash in three stages The fourth addition of alcohol and wateris a controversial postwar development (Kondo 1984)
components of a number of compounds produced during fermentation (49) Theelevated alcohol content of the fermented sake is related to lipid metabolism ofyeast in the presence of proteolipid provided by the koji molds (5051)
Additions (CCP6)
The addition of alcohol at this stage is carried out unless it is clearly statedthat sake does not contain any alcohol from extraneous sources The added alcoholshould not contain methanol or if it does the content of the latter should be lessthan 05 gL because of its toxicity (CCP chemical hazard)
Pressing
Automatic machine presses (consisting of a series of panels with balloon-likesacks attached) are most widely used nowadays instead of the traditional time-consuming method using long bags The remained caked lees are employed forpickle production and cooking or sedimentation of rice particles may occur Alter-natively sedimentation of rice particles at the bottom of the tank may take place
Filtration
Coloring and aging (maturation) inhibition can be effected by using activatedcharcoal filters
Pasteurization (CCP7 and CCP8)
Heating sake preferably twice at 65C kills off the remaining yeast stops en-zyme action and deactivates the lactic acid bacteria that will eventually spoil sakeThis process represents a microbiological hazard for which the specific plant may
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20 KOURTIS AND ARVANITOYANNIS
set CLs However in recent years refrigerated storage and transport have madeunpasteurized sake with characteristic aroma available to the consumer (43)
Dilution
The produced sake in its raw state (Genchu) contains more than 20 alcoholby volume but it is generally diluted to about 15ndash16 vol-
BottlingStorageDistribution
The applied procedures are similar to those mentioned for the beer productionA summary of the occurring hazards CCPs CLs and preventive and correc-
tive measures is given in Table 3
WINE
Introduction
Wines are made from the fruit of Vitis vinifera of which there are a greatnumber of varieties growing in many parts of the world The history of wine isinextricably interwoven with human history It might be as true to say that it waswith wine that civilization began for the vine takes longer to mature than any othercrop and does not produce grapes for wine making until its fourth year It is notexactly known when men first had wine but it was accepted as a gift from the godsthe Egyptians attributed it to Osiris and the Greeks to Dionysos Mesopotamia andthe Caucasian slopes were no doubt early sources of wine from where it was spreadto Egypt and Greece and then to the rest of the world (52)
Wine Main Production Stages
The main stages for wine production are schematically presented in Figure 5
Harvesting (CCP1)
Grape harvesting is a CCP comprising both physical and chemical hazardsPhysically the grapes should be sound without rotten parts otherwise oxidativeand microbial contamination can rapidly develop Therefore harvesting shouldbe conducted with the greatest possible care and an efficient disease managementsystem should be applied (5354) Pesticides play an important role in pest man-agement but they should be handled with care because they constitute chemicalhazards (55) At the time of harvest the grapes must have also reached the correctmaturity when Brix and Total Acidity (TA) levels indicate maturity of wine Sincepesticide and fungicide residues on the surface of the berries constitute chemical
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 21
hazards Oliva et al (56) proposed a rapid and simple gas chromatographic methodfor their determination The maximum residue limits for pesticides in grapes andwines are provided by Codex Alimentarius (45) and Organisation International duVin (57) Finally the bulk bins used for grapes transportation should be effectivelydecontaminated to avoid any microbial infection
Stemming
Stemming includes the removal of stem leaves and grape stalks before crush-ing This procedure has several advantages because the total volume of processedproduct drops by 30 thus resulting in smaller tanks and eventually increasingthe productrsquos alcoholic content (58) However the end of fermentation and the al-cohol content of finished product depend mostly on the Brix level of initial grapesStemmers usually contain a perforated cylinder allowing berries to pass throughbut prevent the passage of stems stalks and leaves
Crushing
Crushing typically immediately follows stemming since some crushing ofthe fruit occurs during stemming The released juice is highly susceptible to oxida-tive browning and microbial contamination The most common crushing processesinvolve pressing the fruit against a perforated wall or passing the fruit through a setof rollers It is very important to avoid crushing the seeds to preclude contaminat-ing the must with seed oils the oxidation of which could produce rancid odors andconstitute an undesirable source of bitter tannins Equally important is the properhandling of product because inappropriate timing might lead to a sudden startof alcoholic fermentation and consequently to higher fermentation temperatureswhile a delay might cause microbial contamination and oxidative browning (59)
Maceration
Maceration is the breakdown of grape solids after crushing of grapes Whilemaceration is always involved in the initial stage of red wine fermentation the long-standing trend has been to limit maceration in white wine production Temperatureand duration of maceration depend on grape and wine variety Usually for white androse wines the maceration time is less than 24 h red destined for early consumptionis macerated for 3ndash5 days and red for aging is macerated from 5 days to 3 weeksFermentation usually occurs during this or at the end of maceration The amount ofthe antimicrobial to be used usually added to white musts that are most sensitive tooxidation depends on the crop health and maceration temperature Sulfur dioxidehas a distinct advantage over other antimicrobial agents because of the relativeinsensitivity of the wine yeasts to its action However it is also toxic or inhibitoryto most bacteria and yeasts (ie Candida Pichia Hansenula) at low concentrations(60) and has a rather low retention capability after the clarification step (61)
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22 KOURTIS AND ARVANITOYANNISTa
ble
3Su
mm
ary
ofH
azar
dsC
CPs
CL
sM
onito
ring
Cor
rect
ive
Act
ions
and
Pers
onne
lRes
pons
ible
for
Sake
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
a(M
CP
)bM
easu
res
CC
PPa
ram
eter
(CL
s)Pr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
CC
ertifi
edsu
pplie
rs
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
wat
er
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Cer
tified
supp
liers
Hea
vym
etal
spr
esen
cein
wat
er
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Eva
luat
ion
ofth
ede
cont
amin
atin
gm
etho
ds
MC
ertifi
edsu
pplie
rs
prop
erpr
epar
atio
n
Mic
robi
alco
ntam
inat
ion
ofth
ecu
lture
100
clea
nM
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Wat
erm
icro
biol
ogic
alqu
ality
Abs
ence
ofpa
thog
ens
Insp
ectio
nof
the
equi
pmen
t
Ric
epo
lishi
ng(C
CP2
)C
Cer
tified
supp
lier
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
polis
hed
rice
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Was
hing
(CC
P3)
PC
ertifi
edsu
pplie
rs
inst
alla
tion
ofau
tom
atic
sepa
rato
r
Ani
mal
impu
ritie
sO
ther
orga
nic
and
inor
gani
cm
ater
01
mm
15
mm
01
mm
Spec
ific
exam
inat
ion
Rew
ashi
ngof
spec
ific
batc
hch
ange
supp
lier
Qua
lity
cont
rol
man
ager
Stea
min
g(f
orun
past
euri
sed
sake
)(C
CP4
)
MG
MP
sche
dule
dm
icro
biol
ogic
alco
ntro
ls
Pres
ence
ofye
asts
and
LA
B
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Spec
ific
batc
hre
proc
essi
ng
CIP
stan
dar-
disa
tion
Qua
lity
cont
rol
man
ager
T
rain
ned
pers
onne
l
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 23
Ferm
enta
tion
(CC
P5)
CM
ater
ialc
ontr
ol
GM
Pco
rros
ion
chec
ks
Hea
vym
etal
pres
ence
Pest
icid
ere
sidu
es
Aslt
02
Cd
lt
001
Pb
lt
03
(mg
L)
Spec
ific
chem
ical
anal
ysis
Dem
etal
lisat
ion
Cha
nge
supp
lier
Rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
GM
Pus
eof
nont
oxic
glyc
ole
Res
idue
sof
ehty
lene
glyc
ole
ampde
terg
ents
0Sp
ecifi
cch
emic
alan
alys
isD
ilutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Alc
ohol
addi
tion
(CC
P6)
CC
ertifi
edsu
pplie
rM
etha
nolc
onte
ntlt
05
gL
GC
exam
inat
ion
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erPa
steu
riza
tion
(CC
P7amp
CC
P8)
MR
unni
ngof
past
euri
ser
acco
rdin
gto
prog
ram
Det
ectio
nof
yeas
tsL
AB
en
zym
atic
activ
ity
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Tem
pera
ture
adju
stm
ent
batc
hre
proc
essi
ng
prop
erm
achi
nery
disi
nfec
tion
Qua
lity
cont
rol
man
ager
Tech
nica
lm
anag
er
aR
egar
ding
the
proc
edur
esof
bottl
ing
stor
age
and
dist
ribu
tion
the
CC
Psar
esi
mila
rto
thos
em
entio
ned
inTa
ble
1fo
rbe
erpr
oduc
tion
bM
CP
stan
dfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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26 KOURTIS AND ARVANITOYANNIS
Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
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ber
2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
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ber
2011
ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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yman
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irel
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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ded
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yman
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irel
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itesi
] at
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
Dow
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yman
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irel
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itesi
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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irel
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] at
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ber
2011
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 15
Storage (CCP15)
The finished beer undergoes chemical microbiological and organoleptic anal-ysis to ensure that its properties are within its specification range A synoptical pre-sentation of the occurring hazards CCPs CLs and preventive corrective measuresis given in Table 1
SAKE
Introduction
Sake is a fermented liquor made from rice and coming in many varietiesdepending on the raw materials manufacturing process and process after brewing(41) According to the earliest records sake was originally brewed from rice thathad been chewed to reach saccharification followed by natural fermentation Sakebrewed this way was used as a sacred wine in the worship of the Shinto gods Thisassociation with religion Shintoism and Buddhism has caused a deep intertwiningof sake with the traditions and social customs of Japan Thus today sake is servedat ceremonies and celebrations of all kinds (42) Sake has the highest alcoholpercentage by volume of any fermented beverage In its natural undiluted state itmay contain a potent 20 ethanol compared to 3ndash5 for beer or 9ndash12 for winewhich may reach higher values for fortified wines (4344) The central brewersrsquounion divides sake into four basic flavor types on four axes of sweet sour bitterand umai The latter is another translatorrsquos nightmare which generally ends uptranslated as delicious According to position established along these axes sakeis considered to be of ldquomature typerdquo ldquofragrant typerdquo ldquolight and smooth typerdquo orldquofull-bodied typerdquo (Fig 3) However no set of criteria can adequately express themultiplicity of sensations that together create the flavor unique to any individualsake but there is a perceived need for terms which quickly and simply give thegeneral idea
Figure 3 Main flavor types for sake characterization (43)
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ORDER REPRINTS
16 KOURTIS AND ARVANITOYANNIS
Sake Main Production Stages
The main stages for sake production are schematically presented in Figure 4
Raw Materials (CCP1)
The main ingredients of Japanese sake are rice sake rice sake yeastand water The rice most suitable for sake should consist of large grains and shouldbe soft with a white part at its center due to coarse cell structure Rice should complywith the maximum residue limits for pesticides and insecticides established by theCodex Alimentarius Commission for this commodity (45) (CCP chemical hazard)For Japanese sake yellow koji mold (Aspergillus oryzae) is used Sake yeast (Sac-charomyces cerevisiae) is a microbe converting the occurring glucose and mineralsin rice and water into alcohol Employment of bubble-free type yeast eliminates
Figure 4 Process flow diagram of sake production (264647)
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the bubble removal step thus shortening the brewing period and reducing the costShould the factory wish to employ a specific yeast an adequate disinfection ofthe building interior is required otherwise undesirable bacteria may be introducedwhich could prove hazardous to human health (CCP microbiological hazard) (46)
Rice Polishing (CCP2)
The brown rice used for sake production must be first polished to remove theouter portion of the grain which contains fats proteins minerals and amino acidsthat can cause unpleasant flavors leaving the starch residues that are located in thecenter of the grain Nowadays machines are programmed to automatically removewhatever portion of the rice is required for the specific sake (47) The rice polishingratio (73ndash35) is expressed by the following formula (43)
Rice polishing ratio=(weight of white riceweight of brown rice)times100 (1)
The polishing process should be gently carried out because friction results inheat generation thereby greatly affecting water absorption and rice grain structureBroken grains are unlikely to satisfactorily ferment (47) Maybe the most importantstage in sake production consists of yeast starter mash production which can takeplace either with the classical Kimoto or slightly revised Yamahai process or withthe new ldquohigh speedrdquo methods (48)
Washing (CCP3)
After the rice has been polished rice powder clinging to the grain surface isremoved by washing Washing can be carried out either mechanically or manually(laborious hand washing) and should result in removing most of the organic andinorganic impurities reaching the CLs set by Codex Alimentarius of 15 and01 mm respectively
Soaking (Steeping)
Soaking allows rice to absorb the desired amount of water that is crucial toestablishing the rice consistency For sake produced ldquoen masserdquo simply dumpinginto a vat overnight for as long as 14 h is a usual case (47) However high polishedrice may be soaked within minutes In such a case an error of a minute might proveto have dire consequences for the end product (43)
Steaming (CCP4)
Steaming aims at softening the rice grains and breaking down the starchmolecules thus encouraging the growth of Aspergillus oryzae and eliminating all
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18 KOURTIS AND ARVANITOYANNIS
other microorganisms leaving an initially sterile environment prone to sake moldpropagation Presence of lactic acid bacteria (LAB) and yeasts may occur at theend of this step representing a microbiological hazard and resulting in consider-able organoleptic losses The time can vary from 20 to 60 min depending on thebrewer and apparatus employed (40ndash60 and 20 min for traditional and automatedrespectively) (4346)
Cooling
The ensuing division of steamed rice is mainly related to its further use Apart of it is directly cooled by air blower whereas 20ndash30 is transferred to a heatedculture room to be infected with bacteria spores (Aspergillus oryzae) for sake moldproduction
Koji
Since rice grains contain no sugar it is the action of koji mold that converts thestarch in the grains to sugar The steamed rice is first cooled to 15ndash36C before beingtransferred to the koji culture room (30C) Spores of the mold are sprinkled likefine dust on the rice when it has cooled down to 33C After the spores are kneadedinto the steamed rice the rice is heaped and wrapped in cloths to prevent heat andmoisture loss which are two crucial factors for satisfactory bacterial growth Tomaintain uniform temperature and moisture rice is spread and mixed twice the firsttime after 20 hours (upon the appearance of white flecks) and then 7ndash8 h thereafteraccompanied by a distinctive aroma release (48)
Main Mash (Moromi) and Fermentation (CCP5)
In fermentation the occurring chemical hazards are related to heavy metalspresence (As lt 02 Cd lt 001 Pb lt 03 mgL) pesticide residues (as mentionedin Codex Alimentarius) and residues of detergents (absence) and ethylene glycole(absence) Their CLs can be determined and monitored with specific chemicalanalyses The ingredients of main mash (water koji rice and steamed rice) areadded to the starter mash in three steps (moving from small to bigger recipient)over a period of 4 days at successively lower temperatures thus preventing thegrowth of airborne bacteria (Table 2) A day after the addition of all the ingredientsformation of a moist surface showing clear cracks occurs Furthermore the mashbegins to bubble (indication of fermentation progress) as gas is given off during theburgeoning fermentation The fermentation can take place at various temperaturesand its duration depends on it that is at lower temperatures it takes up to twoweeks but the sake aroma is much more appealing compared to that formed athigher temperatures The characteristic sake aroma results from combined flavor
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 19
Table 2 Quantities of Ingredients at Each Stage of Mixing the Main Mash (Moromi)
Yeast 1st 2nd 3rd 4thStarter (Moto) Addition Addition Addition Additiona Total
Total rice (kg) 210 470 850 1470 3000Steamed rice (kg) 140 330 650 1230 2350Koji rice (kg) 70 140 200 240 65030 Brewerrsquos 1200 1200
alcohol (L)Water (L) 230 420 1010 2030 360 405
aTraditional brewers mix the final mash in three stages The fourth addition of alcohol and wateris a controversial postwar development (Kondo 1984)
components of a number of compounds produced during fermentation (49) Theelevated alcohol content of the fermented sake is related to lipid metabolism ofyeast in the presence of proteolipid provided by the koji molds (5051)
Additions (CCP6)
The addition of alcohol at this stage is carried out unless it is clearly statedthat sake does not contain any alcohol from extraneous sources The added alcoholshould not contain methanol or if it does the content of the latter should be lessthan 05 gL because of its toxicity (CCP chemical hazard)
Pressing
Automatic machine presses (consisting of a series of panels with balloon-likesacks attached) are most widely used nowadays instead of the traditional time-consuming method using long bags The remained caked lees are employed forpickle production and cooking or sedimentation of rice particles may occur Alter-natively sedimentation of rice particles at the bottom of the tank may take place
Filtration
Coloring and aging (maturation) inhibition can be effected by using activatedcharcoal filters
Pasteurization (CCP7 and CCP8)
Heating sake preferably twice at 65C kills off the remaining yeast stops en-zyme action and deactivates the lactic acid bacteria that will eventually spoil sakeThis process represents a microbiological hazard for which the specific plant may
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20 KOURTIS AND ARVANITOYANNIS
set CLs However in recent years refrigerated storage and transport have madeunpasteurized sake with characteristic aroma available to the consumer (43)
Dilution
The produced sake in its raw state (Genchu) contains more than 20 alcoholby volume but it is generally diluted to about 15ndash16 vol-
BottlingStorageDistribution
The applied procedures are similar to those mentioned for the beer productionA summary of the occurring hazards CCPs CLs and preventive and correc-
tive measures is given in Table 3
WINE
Introduction
Wines are made from the fruit of Vitis vinifera of which there are a greatnumber of varieties growing in many parts of the world The history of wine isinextricably interwoven with human history It might be as true to say that it waswith wine that civilization began for the vine takes longer to mature than any othercrop and does not produce grapes for wine making until its fourth year It is notexactly known when men first had wine but it was accepted as a gift from the godsthe Egyptians attributed it to Osiris and the Greeks to Dionysos Mesopotamia andthe Caucasian slopes were no doubt early sources of wine from where it was spreadto Egypt and Greece and then to the rest of the world (52)
Wine Main Production Stages
The main stages for wine production are schematically presented in Figure 5
Harvesting (CCP1)
Grape harvesting is a CCP comprising both physical and chemical hazardsPhysically the grapes should be sound without rotten parts otherwise oxidativeand microbial contamination can rapidly develop Therefore harvesting shouldbe conducted with the greatest possible care and an efficient disease managementsystem should be applied (5354) Pesticides play an important role in pest man-agement but they should be handled with care because they constitute chemicalhazards (55) At the time of harvest the grapes must have also reached the correctmaturity when Brix and Total Acidity (TA) levels indicate maturity of wine Sincepesticide and fungicide residues on the surface of the berries constitute chemical
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 21
hazards Oliva et al (56) proposed a rapid and simple gas chromatographic methodfor their determination The maximum residue limits for pesticides in grapes andwines are provided by Codex Alimentarius (45) and Organisation International duVin (57) Finally the bulk bins used for grapes transportation should be effectivelydecontaminated to avoid any microbial infection
Stemming
Stemming includes the removal of stem leaves and grape stalks before crush-ing This procedure has several advantages because the total volume of processedproduct drops by 30 thus resulting in smaller tanks and eventually increasingthe productrsquos alcoholic content (58) However the end of fermentation and the al-cohol content of finished product depend mostly on the Brix level of initial grapesStemmers usually contain a perforated cylinder allowing berries to pass throughbut prevent the passage of stems stalks and leaves
Crushing
Crushing typically immediately follows stemming since some crushing ofthe fruit occurs during stemming The released juice is highly susceptible to oxida-tive browning and microbial contamination The most common crushing processesinvolve pressing the fruit against a perforated wall or passing the fruit through a setof rollers It is very important to avoid crushing the seeds to preclude contaminat-ing the must with seed oils the oxidation of which could produce rancid odors andconstitute an undesirable source of bitter tannins Equally important is the properhandling of product because inappropriate timing might lead to a sudden startof alcoholic fermentation and consequently to higher fermentation temperatureswhile a delay might cause microbial contamination and oxidative browning (59)
Maceration
Maceration is the breakdown of grape solids after crushing of grapes Whilemaceration is always involved in the initial stage of red wine fermentation the long-standing trend has been to limit maceration in white wine production Temperatureand duration of maceration depend on grape and wine variety Usually for white androse wines the maceration time is less than 24 h red destined for early consumptionis macerated for 3ndash5 days and red for aging is macerated from 5 days to 3 weeksFermentation usually occurs during this or at the end of maceration The amount ofthe antimicrobial to be used usually added to white musts that are most sensitive tooxidation depends on the crop health and maceration temperature Sulfur dioxidehas a distinct advantage over other antimicrobial agents because of the relativeinsensitivity of the wine yeasts to its action However it is also toxic or inhibitoryto most bacteria and yeasts (ie Candida Pichia Hansenula) at low concentrations(60) and has a rather low retention capability after the clarification step (61)
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22 KOURTIS AND ARVANITOYANNISTa
ble
3Su
mm
ary
ofH
azar
dsC
CPs
CL
sM
onito
ring
Cor
rect
ive
Act
ions
and
Pers
onne
lRes
pons
ible
for
Sake
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
a(M
CP
)bM
easu
res
CC
PPa
ram
eter
(CL
s)Pr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
CC
ertifi
edsu
pplie
rs
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
wat
er
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Cer
tified
supp
liers
Hea
vym
etal
spr
esen
cein
wat
er
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Eva
luat
ion
ofth
ede
cont
amin
atin
gm
etho
ds
MC
ertifi
edsu
pplie
rs
prop
erpr
epar
atio
n
Mic
robi
alco
ntam
inat
ion
ofth
ecu
lture
100
clea
nM
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Wat
erm
icro
biol
ogic
alqu
ality
Abs
ence
ofpa
thog
ens
Insp
ectio
nof
the
equi
pmen
t
Ric
epo
lishi
ng(C
CP2
)C
Cer
tified
supp
lier
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
polis
hed
rice
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Was
hing
(CC
P3)
PC
ertifi
edsu
pplie
rs
inst
alla
tion
ofau
tom
atic
sepa
rato
r
Ani
mal
impu
ritie
sO
ther
orga
nic
and
inor
gani
cm
ater
01
mm
15
mm
01
mm
Spec
ific
exam
inat
ion
Rew
ashi
ngof
spec
ific
batc
hch
ange
supp
lier
Qua
lity
cont
rol
man
ager
Stea
min
g(f
orun
past
euri
sed
sake
)(C
CP4
)
MG
MP
sche
dule
dm
icro
biol
ogic
alco
ntro
ls
Pres
ence
ofye
asts
and
LA
B
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Spec
ific
batc
hre
proc
essi
ng
CIP
stan
dar-
disa
tion
Qua
lity
cont
rol
man
ager
T
rain
ned
pers
onne
l
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 23
Ferm
enta
tion
(CC
P5)
CM
ater
ialc
ontr
ol
GM
Pco
rros
ion
chec
ks
Hea
vym
etal
pres
ence
Pest
icid
ere
sidu
es
Aslt
02
Cd
lt
001
Pb
lt
03
(mg
L)
Spec
ific
chem
ical
anal
ysis
Dem
etal
lisat
ion
Cha
nge
supp
lier
Rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
GM
Pus
eof
nont
oxic
glyc
ole
Res
idue
sof
ehty
lene
glyc
ole
ampde
terg
ents
0Sp
ecifi
cch
emic
alan
alys
isD
ilutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Alc
ohol
addi
tion
(CC
P6)
CC
ertifi
edsu
pplie
rM
etha
nolc
onte
ntlt
05
gL
GC
exam
inat
ion
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erPa
steu
riza
tion
(CC
P7amp
CC
P8)
MR
unni
ngof
past
euri
ser
acco
rdin
gto
prog
ram
Det
ectio
nof
yeas
tsL
AB
en
zym
atic
activ
ity
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Tem
pera
ture
adju
stm
ent
batc
hre
proc
essi
ng
prop
erm
achi
nery
disi
nfec
tion
Qua
lity
cont
rol
man
ager
Tech
nica
lm
anag
er
aR
egar
ding
the
proc
edur
esof
bottl
ing
stor
age
and
dist
ribu
tion
the
CC
Psar
esi
mila
rto
thos
em
entio
ned
inTa
ble
1fo
rbe
erpr
oduc
tion
bM
CP
stan
dfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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ORDER REPRINTS
28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
Dow
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
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ded
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yman
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irel
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] at
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
nloa
ded
by [
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yman
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irel
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vers
itesi
] at
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ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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16 KOURTIS AND ARVANITOYANNIS
Sake Main Production Stages
The main stages for sake production are schematically presented in Figure 4
Raw Materials (CCP1)
The main ingredients of Japanese sake are rice sake rice sake yeastand water The rice most suitable for sake should consist of large grains and shouldbe soft with a white part at its center due to coarse cell structure Rice should complywith the maximum residue limits for pesticides and insecticides established by theCodex Alimentarius Commission for this commodity (45) (CCP chemical hazard)For Japanese sake yellow koji mold (Aspergillus oryzae) is used Sake yeast (Sac-charomyces cerevisiae) is a microbe converting the occurring glucose and mineralsin rice and water into alcohol Employment of bubble-free type yeast eliminates
Figure 4 Process flow diagram of sake production (264647)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 17
the bubble removal step thus shortening the brewing period and reducing the costShould the factory wish to employ a specific yeast an adequate disinfection ofthe building interior is required otherwise undesirable bacteria may be introducedwhich could prove hazardous to human health (CCP microbiological hazard) (46)
Rice Polishing (CCP2)
The brown rice used for sake production must be first polished to remove theouter portion of the grain which contains fats proteins minerals and amino acidsthat can cause unpleasant flavors leaving the starch residues that are located in thecenter of the grain Nowadays machines are programmed to automatically removewhatever portion of the rice is required for the specific sake (47) The rice polishingratio (73ndash35) is expressed by the following formula (43)
Rice polishing ratio=(weight of white riceweight of brown rice)times100 (1)
The polishing process should be gently carried out because friction results inheat generation thereby greatly affecting water absorption and rice grain structureBroken grains are unlikely to satisfactorily ferment (47) Maybe the most importantstage in sake production consists of yeast starter mash production which can takeplace either with the classical Kimoto or slightly revised Yamahai process or withthe new ldquohigh speedrdquo methods (48)
Washing (CCP3)
After the rice has been polished rice powder clinging to the grain surface isremoved by washing Washing can be carried out either mechanically or manually(laborious hand washing) and should result in removing most of the organic andinorganic impurities reaching the CLs set by Codex Alimentarius of 15 and01 mm respectively
Soaking (Steeping)
Soaking allows rice to absorb the desired amount of water that is crucial toestablishing the rice consistency For sake produced ldquoen masserdquo simply dumpinginto a vat overnight for as long as 14 h is a usual case (47) However high polishedrice may be soaked within minutes In such a case an error of a minute might proveto have dire consequences for the end product (43)
Steaming (CCP4)
Steaming aims at softening the rice grains and breaking down the starchmolecules thus encouraging the growth of Aspergillus oryzae and eliminating all
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18 KOURTIS AND ARVANITOYANNIS
other microorganisms leaving an initially sterile environment prone to sake moldpropagation Presence of lactic acid bacteria (LAB) and yeasts may occur at theend of this step representing a microbiological hazard and resulting in consider-able organoleptic losses The time can vary from 20 to 60 min depending on thebrewer and apparatus employed (40ndash60 and 20 min for traditional and automatedrespectively) (4346)
Cooling
The ensuing division of steamed rice is mainly related to its further use Apart of it is directly cooled by air blower whereas 20ndash30 is transferred to a heatedculture room to be infected with bacteria spores (Aspergillus oryzae) for sake moldproduction
Koji
Since rice grains contain no sugar it is the action of koji mold that converts thestarch in the grains to sugar The steamed rice is first cooled to 15ndash36C before beingtransferred to the koji culture room (30C) Spores of the mold are sprinkled likefine dust on the rice when it has cooled down to 33C After the spores are kneadedinto the steamed rice the rice is heaped and wrapped in cloths to prevent heat andmoisture loss which are two crucial factors for satisfactory bacterial growth Tomaintain uniform temperature and moisture rice is spread and mixed twice the firsttime after 20 hours (upon the appearance of white flecks) and then 7ndash8 h thereafteraccompanied by a distinctive aroma release (48)
Main Mash (Moromi) and Fermentation (CCP5)
In fermentation the occurring chemical hazards are related to heavy metalspresence (As lt 02 Cd lt 001 Pb lt 03 mgL) pesticide residues (as mentionedin Codex Alimentarius) and residues of detergents (absence) and ethylene glycole(absence) Their CLs can be determined and monitored with specific chemicalanalyses The ingredients of main mash (water koji rice and steamed rice) areadded to the starter mash in three steps (moving from small to bigger recipient)over a period of 4 days at successively lower temperatures thus preventing thegrowth of airborne bacteria (Table 2) A day after the addition of all the ingredientsformation of a moist surface showing clear cracks occurs Furthermore the mashbegins to bubble (indication of fermentation progress) as gas is given off during theburgeoning fermentation The fermentation can take place at various temperaturesand its duration depends on it that is at lower temperatures it takes up to twoweeks but the sake aroma is much more appealing compared to that formed athigher temperatures The characteristic sake aroma results from combined flavor
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 19
Table 2 Quantities of Ingredients at Each Stage of Mixing the Main Mash (Moromi)
Yeast 1st 2nd 3rd 4thStarter (Moto) Addition Addition Addition Additiona Total
Total rice (kg) 210 470 850 1470 3000Steamed rice (kg) 140 330 650 1230 2350Koji rice (kg) 70 140 200 240 65030 Brewerrsquos 1200 1200
alcohol (L)Water (L) 230 420 1010 2030 360 405
aTraditional brewers mix the final mash in three stages The fourth addition of alcohol and wateris a controversial postwar development (Kondo 1984)
components of a number of compounds produced during fermentation (49) Theelevated alcohol content of the fermented sake is related to lipid metabolism ofyeast in the presence of proteolipid provided by the koji molds (5051)
Additions (CCP6)
The addition of alcohol at this stage is carried out unless it is clearly statedthat sake does not contain any alcohol from extraneous sources The added alcoholshould not contain methanol or if it does the content of the latter should be lessthan 05 gL because of its toxicity (CCP chemical hazard)
Pressing
Automatic machine presses (consisting of a series of panels with balloon-likesacks attached) are most widely used nowadays instead of the traditional time-consuming method using long bags The remained caked lees are employed forpickle production and cooking or sedimentation of rice particles may occur Alter-natively sedimentation of rice particles at the bottom of the tank may take place
Filtration
Coloring and aging (maturation) inhibition can be effected by using activatedcharcoal filters
Pasteurization (CCP7 and CCP8)
Heating sake preferably twice at 65C kills off the remaining yeast stops en-zyme action and deactivates the lactic acid bacteria that will eventually spoil sakeThis process represents a microbiological hazard for which the specific plant may
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ORDER REPRINTS
20 KOURTIS AND ARVANITOYANNIS
set CLs However in recent years refrigerated storage and transport have madeunpasteurized sake with characteristic aroma available to the consumer (43)
Dilution
The produced sake in its raw state (Genchu) contains more than 20 alcoholby volume but it is generally diluted to about 15ndash16 vol-
BottlingStorageDistribution
The applied procedures are similar to those mentioned for the beer productionA summary of the occurring hazards CCPs CLs and preventive and correc-
tive measures is given in Table 3
WINE
Introduction
Wines are made from the fruit of Vitis vinifera of which there are a greatnumber of varieties growing in many parts of the world The history of wine isinextricably interwoven with human history It might be as true to say that it waswith wine that civilization began for the vine takes longer to mature than any othercrop and does not produce grapes for wine making until its fourth year It is notexactly known when men first had wine but it was accepted as a gift from the godsthe Egyptians attributed it to Osiris and the Greeks to Dionysos Mesopotamia andthe Caucasian slopes were no doubt early sources of wine from where it was spreadto Egypt and Greece and then to the rest of the world (52)
Wine Main Production Stages
The main stages for wine production are schematically presented in Figure 5
Harvesting (CCP1)
Grape harvesting is a CCP comprising both physical and chemical hazardsPhysically the grapes should be sound without rotten parts otherwise oxidativeand microbial contamination can rapidly develop Therefore harvesting shouldbe conducted with the greatest possible care and an efficient disease managementsystem should be applied (5354) Pesticides play an important role in pest man-agement but they should be handled with care because they constitute chemicalhazards (55) At the time of harvest the grapes must have also reached the correctmaturity when Brix and Total Acidity (TA) levels indicate maturity of wine Sincepesticide and fungicide residues on the surface of the berries constitute chemical
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 21
hazards Oliva et al (56) proposed a rapid and simple gas chromatographic methodfor their determination The maximum residue limits for pesticides in grapes andwines are provided by Codex Alimentarius (45) and Organisation International duVin (57) Finally the bulk bins used for grapes transportation should be effectivelydecontaminated to avoid any microbial infection
Stemming
Stemming includes the removal of stem leaves and grape stalks before crush-ing This procedure has several advantages because the total volume of processedproduct drops by 30 thus resulting in smaller tanks and eventually increasingthe productrsquos alcoholic content (58) However the end of fermentation and the al-cohol content of finished product depend mostly on the Brix level of initial grapesStemmers usually contain a perforated cylinder allowing berries to pass throughbut prevent the passage of stems stalks and leaves
Crushing
Crushing typically immediately follows stemming since some crushing ofthe fruit occurs during stemming The released juice is highly susceptible to oxida-tive browning and microbial contamination The most common crushing processesinvolve pressing the fruit against a perforated wall or passing the fruit through a setof rollers It is very important to avoid crushing the seeds to preclude contaminat-ing the must with seed oils the oxidation of which could produce rancid odors andconstitute an undesirable source of bitter tannins Equally important is the properhandling of product because inappropriate timing might lead to a sudden startof alcoholic fermentation and consequently to higher fermentation temperatureswhile a delay might cause microbial contamination and oxidative browning (59)
Maceration
Maceration is the breakdown of grape solids after crushing of grapes Whilemaceration is always involved in the initial stage of red wine fermentation the long-standing trend has been to limit maceration in white wine production Temperatureand duration of maceration depend on grape and wine variety Usually for white androse wines the maceration time is less than 24 h red destined for early consumptionis macerated for 3ndash5 days and red for aging is macerated from 5 days to 3 weeksFermentation usually occurs during this or at the end of maceration The amount ofthe antimicrobial to be used usually added to white musts that are most sensitive tooxidation depends on the crop health and maceration temperature Sulfur dioxidehas a distinct advantage over other antimicrobial agents because of the relativeinsensitivity of the wine yeasts to its action However it is also toxic or inhibitoryto most bacteria and yeasts (ie Candida Pichia Hansenula) at low concentrations(60) and has a rather low retention capability after the clarification step (61)
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ORDER REPRINTS
22 KOURTIS AND ARVANITOYANNISTa
ble
3Su
mm
ary
ofH
azar
dsC
CPs
CL
sM
onito
ring
Cor
rect
ive
Act
ions
and
Pers
onne
lRes
pons
ible
for
Sake
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
a(M
CP
)bM
easu
res
CC
PPa
ram
eter
(CL
s)Pr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
CC
ertifi
edsu
pplie
rs
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
wat
er
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Cer
tified
supp
liers
Hea
vym
etal
spr
esen
cein
wat
er
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Eva
luat
ion
ofth
ede
cont
amin
atin
gm
etho
ds
MC
ertifi
edsu
pplie
rs
prop
erpr
epar
atio
n
Mic
robi
alco
ntam
inat
ion
ofth
ecu
lture
100
clea
nM
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Wat
erm
icro
biol
ogic
alqu
ality
Abs
ence
ofpa
thog
ens
Insp
ectio
nof
the
equi
pmen
t
Ric
epo
lishi
ng(C
CP2
)C
Cer
tified
supp
lier
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
polis
hed
rice
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Was
hing
(CC
P3)
PC
ertifi
edsu
pplie
rs
inst
alla
tion
ofau
tom
atic
sepa
rato
r
Ani
mal
impu
ritie
sO
ther
orga
nic
and
inor
gani
cm
ater
01
mm
15
mm
01
mm
Spec
ific
exam
inat
ion
Rew
ashi
ngof
spec
ific
batc
hch
ange
supp
lier
Qua
lity
cont
rol
man
ager
Stea
min
g(f
orun
past
euri
sed
sake
)(C
CP4
)
MG
MP
sche
dule
dm
icro
biol
ogic
alco
ntro
ls
Pres
ence
ofye
asts
and
LA
B
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Spec
ific
batc
hre
proc
essi
ng
CIP
stan
dar-
disa
tion
Qua
lity
cont
rol
man
ager
T
rain
ned
pers
onne
l
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 23
Ferm
enta
tion
(CC
P5)
CM
ater
ialc
ontr
ol
GM
Pco
rros
ion
chec
ks
Hea
vym
etal
pres
ence
Pest
icid
ere
sidu
es
Aslt
02
Cd
lt
001
Pb
lt
03
(mg
L)
Spec
ific
chem
ical
anal
ysis
Dem
etal
lisat
ion
Cha
nge
supp
lier
Rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
GM
Pus
eof
nont
oxic
glyc
ole
Res
idue
sof
ehty
lene
glyc
ole
ampde
terg
ents
0Sp
ecifi
cch
emic
alan
alys
isD
ilutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Alc
ohol
addi
tion
(CC
P6)
CC
ertifi
edsu
pplie
rM
etha
nolc
onte
ntlt
05
gL
GC
exam
inat
ion
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erPa
steu
riza
tion
(CC
P7amp
CC
P8)
MR
unni
ngof
past
euri
ser
acco
rdin
gto
prog
ram
Det
ectio
nof
yeas
tsL
AB
en
zym
atic
activ
ity
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Tem
pera
ture
adju
stm
ent
batc
hre
proc
essi
ng
prop
erm
achi
nery
disi
nfec
tion
Qua
lity
cont
rol
man
ager
Tech
nica
lm
anag
er
aR
egar
ding
the
proc
edur
esof
bottl
ing
stor
age
and
dist
ribu
tion
the
CC
Psar
esi
mila
rto
thos
em
entio
ned
inTa
ble
1fo
rbe
erpr
oduc
tion
bM
CP
stan
dfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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26 KOURTIS AND ARVANITOYANNIS
Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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ORDER REPRINTS
28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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ORDER REPRINTS
34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
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ded
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
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ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 17
the bubble removal step thus shortening the brewing period and reducing the costShould the factory wish to employ a specific yeast an adequate disinfection ofthe building interior is required otherwise undesirable bacteria may be introducedwhich could prove hazardous to human health (CCP microbiological hazard) (46)
Rice Polishing (CCP2)
The brown rice used for sake production must be first polished to remove theouter portion of the grain which contains fats proteins minerals and amino acidsthat can cause unpleasant flavors leaving the starch residues that are located in thecenter of the grain Nowadays machines are programmed to automatically removewhatever portion of the rice is required for the specific sake (47) The rice polishingratio (73ndash35) is expressed by the following formula (43)
Rice polishing ratio=(weight of white riceweight of brown rice)times100 (1)
The polishing process should be gently carried out because friction results inheat generation thereby greatly affecting water absorption and rice grain structureBroken grains are unlikely to satisfactorily ferment (47) Maybe the most importantstage in sake production consists of yeast starter mash production which can takeplace either with the classical Kimoto or slightly revised Yamahai process or withthe new ldquohigh speedrdquo methods (48)
Washing (CCP3)
After the rice has been polished rice powder clinging to the grain surface isremoved by washing Washing can be carried out either mechanically or manually(laborious hand washing) and should result in removing most of the organic andinorganic impurities reaching the CLs set by Codex Alimentarius of 15 and01 mm respectively
Soaking (Steeping)
Soaking allows rice to absorb the desired amount of water that is crucial toestablishing the rice consistency For sake produced ldquoen masserdquo simply dumpinginto a vat overnight for as long as 14 h is a usual case (47) However high polishedrice may be soaked within minutes In such a case an error of a minute might proveto have dire consequences for the end product (43)
Steaming (CCP4)
Steaming aims at softening the rice grains and breaking down the starchmolecules thus encouraging the growth of Aspergillus oryzae and eliminating all
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ORDER REPRINTS
18 KOURTIS AND ARVANITOYANNIS
other microorganisms leaving an initially sterile environment prone to sake moldpropagation Presence of lactic acid bacteria (LAB) and yeasts may occur at theend of this step representing a microbiological hazard and resulting in consider-able organoleptic losses The time can vary from 20 to 60 min depending on thebrewer and apparatus employed (40ndash60 and 20 min for traditional and automatedrespectively) (4346)
Cooling
The ensuing division of steamed rice is mainly related to its further use Apart of it is directly cooled by air blower whereas 20ndash30 is transferred to a heatedculture room to be infected with bacteria spores (Aspergillus oryzae) for sake moldproduction
Koji
Since rice grains contain no sugar it is the action of koji mold that converts thestarch in the grains to sugar The steamed rice is first cooled to 15ndash36C before beingtransferred to the koji culture room (30C) Spores of the mold are sprinkled likefine dust on the rice when it has cooled down to 33C After the spores are kneadedinto the steamed rice the rice is heaped and wrapped in cloths to prevent heat andmoisture loss which are two crucial factors for satisfactory bacterial growth Tomaintain uniform temperature and moisture rice is spread and mixed twice the firsttime after 20 hours (upon the appearance of white flecks) and then 7ndash8 h thereafteraccompanied by a distinctive aroma release (48)
Main Mash (Moromi) and Fermentation (CCP5)
In fermentation the occurring chemical hazards are related to heavy metalspresence (As lt 02 Cd lt 001 Pb lt 03 mgL) pesticide residues (as mentionedin Codex Alimentarius) and residues of detergents (absence) and ethylene glycole(absence) Their CLs can be determined and monitored with specific chemicalanalyses The ingredients of main mash (water koji rice and steamed rice) areadded to the starter mash in three steps (moving from small to bigger recipient)over a period of 4 days at successively lower temperatures thus preventing thegrowth of airborne bacteria (Table 2) A day after the addition of all the ingredientsformation of a moist surface showing clear cracks occurs Furthermore the mashbegins to bubble (indication of fermentation progress) as gas is given off during theburgeoning fermentation The fermentation can take place at various temperaturesand its duration depends on it that is at lower temperatures it takes up to twoweeks but the sake aroma is much more appealing compared to that formed athigher temperatures The characteristic sake aroma results from combined flavor
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 19
Table 2 Quantities of Ingredients at Each Stage of Mixing the Main Mash (Moromi)
Yeast 1st 2nd 3rd 4thStarter (Moto) Addition Addition Addition Additiona Total
Total rice (kg) 210 470 850 1470 3000Steamed rice (kg) 140 330 650 1230 2350Koji rice (kg) 70 140 200 240 65030 Brewerrsquos 1200 1200
alcohol (L)Water (L) 230 420 1010 2030 360 405
aTraditional brewers mix the final mash in three stages The fourth addition of alcohol and wateris a controversial postwar development (Kondo 1984)
components of a number of compounds produced during fermentation (49) Theelevated alcohol content of the fermented sake is related to lipid metabolism ofyeast in the presence of proteolipid provided by the koji molds (5051)
Additions (CCP6)
The addition of alcohol at this stage is carried out unless it is clearly statedthat sake does not contain any alcohol from extraneous sources The added alcoholshould not contain methanol or if it does the content of the latter should be lessthan 05 gL because of its toxicity (CCP chemical hazard)
Pressing
Automatic machine presses (consisting of a series of panels with balloon-likesacks attached) are most widely used nowadays instead of the traditional time-consuming method using long bags The remained caked lees are employed forpickle production and cooking or sedimentation of rice particles may occur Alter-natively sedimentation of rice particles at the bottom of the tank may take place
Filtration
Coloring and aging (maturation) inhibition can be effected by using activatedcharcoal filters
Pasteurization (CCP7 and CCP8)
Heating sake preferably twice at 65C kills off the remaining yeast stops en-zyme action and deactivates the lactic acid bacteria that will eventually spoil sakeThis process represents a microbiological hazard for which the specific plant may
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ORDER REPRINTS
20 KOURTIS AND ARVANITOYANNIS
set CLs However in recent years refrigerated storage and transport have madeunpasteurized sake with characteristic aroma available to the consumer (43)
Dilution
The produced sake in its raw state (Genchu) contains more than 20 alcoholby volume but it is generally diluted to about 15ndash16 vol-
BottlingStorageDistribution
The applied procedures are similar to those mentioned for the beer productionA summary of the occurring hazards CCPs CLs and preventive and correc-
tive measures is given in Table 3
WINE
Introduction
Wines are made from the fruit of Vitis vinifera of which there are a greatnumber of varieties growing in many parts of the world The history of wine isinextricably interwoven with human history It might be as true to say that it waswith wine that civilization began for the vine takes longer to mature than any othercrop and does not produce grapes for wine making until its fourth year It is notexactly known when men first had wine but it was accepted as a gift from the godsthe Egyptians attributed it to Osiris and the Greeks to Dionysos Mesopotamia andthe Caucasian slopes were no doubt early sources of wine from where it was spreadto Egypt and Greece and then to the rest of the world (52)
Wine Main Production Stages
The main stages for wine production are schematically presented in Figure 5
Harvesting (CCP1)
Grape harvesting is a CCP comprising both physical and chemical hazardsPhysically the grapes should be sound without rotten parts otherwise oxidativeand microbial contamination can rapidly develop Therefore harvesting shouldbe conducted with the greatest possible care and an efficient disease managementsystem should be applied (5354) Pesticides play an important role in pest man-agement but they should be handled with care because they constitute chemicalhazards (55) At the time of harvest the grapes must have also reached the correctmaturity when Brix and Total Acidity (TA) levels indicate maturity of wine Sincepesticide and fungicide residues on the surface of the berries constitute chemical
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 21
hazards Oliva et al (56) proposed a rapid and simple gas chromatographic methodfor their determination The maximum residue limits for pesticides in grapes andwines are provided by Codex Alimentarius (45) and Organisation International duVin (57) Finally the bulk bins used for grapes transportation should be effectivelydecontaminated to avoid any microbial infection
Stemming
Stemming includes the removal of stem leaves and grape stalks before crush-ing This procedure has several advantages because the total volume of processedproduct drops by 30 thus resulting in smaller tanks and eventually increasingthe productrsquos alcoholic content (58) However the end of fermentation and the al-cohol content of finished product depend mostly on the Brix level of initial grapesStemmers usually contain a perforated cylinder allowing berries to pass throughbut prevent the passage of stems stalks and leaves
Crushing
Crushing typically immediately follows stemming since some crushing ofthe fruit occurs during stemming The released juice is highly susceptible to oxida-tive browning and microbial contamination The most common crushing processesinvolve pressing the fruit against a perforated wall or passing the fruit through a setof rollers It is very important to avoid crushing the seeds to preclude contaminat-ing the must with seed oils the oxidation of which could produce rancid odors andconstitute an undesirable source of bitter tannins Equally important is the properhandling of product because inappropriate timing might lead to a sudden startof alcoholic fermentation and consequently to higher fermentation temperatureswhile a delay might cause microbial contamination and oxidative browning (59)
Maceration
Maceration is the breakdown of grape solids after crushing of grapes Whilemaceration is always involved in the initial stage of red wine fermentation the long-standing trend has been to limit maceration in white wine production Temperatureand duration of maceration depend on grape and wine variety Usually for white androse wines the maceration time is less than 24 h red destined for early consumptionis macerated for 3ndash5 days and red for aging is macerated from 5 days to 3 weeksFermentation usually occurs during this or at the end of maceration The amount ofthe antimicrobial to be used usually added to white musts that are most sensitive tooxidation depends on the crop health and maceration temperature Sulfur dioxidehas a distinct advantage over other antimicrobial agents because of the relativeinsensitivity of the wine yeasts to its action However it is also toxic or inhibitoryto most bacteria and yeasts (ie Candida Pichia Hansenula) at low concentrations(60) and has a rather low retention capability after the clarification step (61)
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ORDER REPRINTS
22 KOURTIS AND ARVANITOYANNISTa
ble
3Su
mm
ary
ofH
azar
dsC
CPs
CL
sM
onito
ring
Cor
rect
ive
Act
ions
and
Pers
onne
lRes
pons
ible
for
Sake
Prod
uctio
n
Con
trol
-H
azar
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Lim
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Cor
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Proc
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Inco
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ater
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(CC
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ase
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agem
ent
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Pest
icid
ere
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er
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scri
bed
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enta
rius
Spec
ific
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ysis
Rej
ectio
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ific
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Prop
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Hea
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er
With
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luat
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ertifi
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Was
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(CC
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ertifi
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inst
alla
tion
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atic
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rato
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Ani
mal
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ritie
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ther
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nic
and
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cm
ater
01
mm
15
mm
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mm
Spec
ific
exam
inat
ion
Rew
ashi
ngof
spec
ific
batc
hch
ange
supp
lier
Qua
lity
cont
rol
man
ager
Stea
min
g(f
orun
past
euri
sed
sake
)(C
CP4
)
MG
MP
sche
dule
dm
icro
biol
ogic
alco
ntro
ls
Pres
ence
ofye
asts
and
LA
B
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Spec
ific
batc
hre
proc
essi
ng
CIP
stan
dar-
disa
tion
Qua
lity
cont
rol
man
ager
T
rain
ned
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 23
Ferm
enta
tion
(CC
P5)
CM
ater
ialc
ontr
ol
GM
Pco
rros
ion
chec
ks
Hea
vym
etal
pres
ence
Pest
icid
ere
sidu
es
Aslt
02
Cd
lt
001
Pb
lt
03
(mg
L)
Spec
ific
chem
ical
anal
ysis
Dem
etal
lisat
ion
Cha
nge
supp
lier
Rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
GM
Pus
eof
nont
oxic
glyc
ole
Res
idue
sof
ehty
lene
glyc
ole
ampde
terg
ents
0Sp
ecifi
cch
emic
alan
alys
isD
ilutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Alc
ohol
addi
tion
(CC
P6)
CC
ertifi
edsu
pplie
rM
etha
nolc
onte
ntlt
05
gL
GC
exam
inat
ion
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erPa
steu
riza
tion
(CC
P7amp
CC
P8)
MR
unni
ngof
past
euri
ser
acco
rdin
gto
prog
ram
Det
ectio
nof
yeas
tsL
AB
en
zym
atic
activ
ity
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Tem
pera
ture
adju
stm
ent
batc
hre
proc
essi
ng
prop
erm
achi
nery
disi
nfec
tion
Qua
lity
cont
rol
man
ager
Tech
nica
lm
anag
er
aR
egar
ding
the
proc
edur
esof
bottl
ing
stor
age
and
dist
ribu
tion
the
CC
Psar
esi
mila
rto
thos
em
entio
ned
inTa
ble
1fo
rbe
erpr
oduc
tion
bM
CP
stan
dfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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ORDER REPRINTS
26 KOURTIS AND ARVANITOYANNIS
Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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2011
ORDER REPRINTS
28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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2011
ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
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yman
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irel
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
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ded
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yman
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irel
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ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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irel
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itesi
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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18 KOURTIS AND ARVANITOYANNIS
other microorganisms leaving an initially sterile environment prone to sake moldpropagation Presence of lactic acid bacteria (LAB) and yeasts may occur at theend of this step representing a microbiological hazard and resulting in consider-able organoleptic losses The time can vary from 20 to 60 min depending on thebrewer and apparatus employed (40ndash60 and 20 min for traditional and automatedrespectively) (4346)
Cooling
The ensuing division of steamed rice is mainly related to its further use Apart of it is directly cooled by air blower whereas 20ndash30 is transferred to a heatedculture room to be infected with bacteria spores (Aspergillus oryzae) for sake moldproduction
Koji
Since rice grains contain no sugar it is the action of koji mold that converts thestarch in the grains to sugar The steamed rice is first cooled to 15ndash36C before beingtransferred to the koji culture room (30C) Spores of the mold are sprinkled likefine dust on the rice when it has cooled down to 33C After the spores are kneadedinto the steamed rice the rice is heaped and wrapped in cloths to prevent heat andmoisture loss which are two crucial factors for satisfactory bacterial growth Tomaintain uniform temperature and moisture rice is spread and mixed twice the firsttime after 20 hours (upon the appearance of white flecks) and then 7ndash8 h thereafteraccompanied by a distinctive aroma release (48)
Main Mash (Moromi) and Fermentation (CCP5)
In fermentation the occurring chemical hazards are related to heavy metalspresence (As lt 02 Cd lt 001 Pb lt 03 mgL) pesticide residues (as mentionedin Codex Alimentarius) and residues of detergents (absence) and ethylene glycole(absence) Their CLs can be determined and monitored with specific chemicalanalyses The ingredients of main mash (water koji rice and steamed rice) areadded to the starter mash in three steps (moving from small to bigger recipient)over a period of 4 days at successively lower temperatures thus preventing thegrowth of airborne bacteria (Table 2) A day after the addition of all the ingredientsformation of a moist surface showing clear cracks occurs Furthermore the mashbegins to bubble (indication of fermentation progress) as gas is given off during theburgeoning fermentation The fermentation can take place at various temperaturesand its duration depends on it that is at lower temperatures it takes up to twoweeks but the sake aroma is much more appealing compared to that formed athigher temperatures The characteristic sake aroma results from combined flavor
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 19
Table 2 Quantities of Ingredients at Each Stage of Mixing the Main Mash (Moromi)
Yeast 1st 2nd 3rd 4thStarter (Moto) Addition Addition Addition Additiona Total
Total rice (kg) 210 470 850 1470 3000Steamed rice (kg) 140 330 650 1230 2350Koji rice (kg) 70 140 200 240 65030 Brewerrsquos 1200 1200
alcohol (L)Water (L) 230 420 1010 2030 360 405
aTraditional brewers mix the final mash in three stages The fourth addition of alcohol and wateris a controversial postwar development (Kondo 1984)
components of a number of compounds produced during fermentation (49) Theelevated alcohol content of the fermented sake is related to lipid metabolism ofyeast in the presence of proteolipid provided by the koji molds (5051)
Additions (CCP6)
The addition of alcohol at this stage is carried out unless it is clearly statedthat sake does not contain any alcohol from extraneous sources The added alcoholshould not contain methanol or if it does the content of the latter should be lessthan 05 gL because of its toxicity (CCP chemical hazard)
Pressing
Automatic machine presses (consisting of a series of panels with balloon-likesacks attached) are most widely used nowadays instead of the traditional time-consuming method using long bags The remained caked lees are employed forpickle production and cooking or sedimentation of rice particles may occur Alter-natively sedimentation of rice particles at the bottom of the tank may take place
Filtration
Coloring and aging (maturation) inhibition can be effected by using activatedcharcoal filters
Pasteurization (CCP7 and CCP8)
Heating sake preferably twice at 65C kills off the remaining yeast stops en-zyme action and deactivates the lactic acid bacteria that will eventually spoil sakeThis process represents a microbiological hazard for which the specific plant may
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20 KOURTIS AND ARVANITOYANNIS
set CLs However in recent years refrigerated storage and transport have madeunpasteurized sake with characteristic aroma available to the consumer (43)
Dilution
The produced sake in its raw state (Genchu) contains more than 20 alcoholby volume but it is generally diluted to about 15ndash16 vol-
BottlingStorageDistribution
The applied procedures are similar to those mentioned for the beer productionA summary of the occurring hazards CCPs CLs and preventive and correc-
tive measures is given in Table 3
WINE
Introduction
Wines are made from the fruit of Vitis vinifera of which there are a greatnumber of varieties growing in many parts of the world The history of wine isinextricably interwoven with human history It might be as true to say that it waswith wine that civilization began for the vine takes longer to mature than any othercrop and does not produce grapes for wine making until its fourth year It is notexactly known when men first had wine but it was accepted as a gift from the godsthe Egyptians attributed it to Osiris and the Greeks to Dionysos Mesopotamia andthe Caucasian slopes were no doubt early sources of wine from where it was spreadto Egypt and Greece and then to the rest of the world (52)
Wine Main Production Stages
The main stages for wine production are schematically presented in Figure 5
Harvesting (CCP1)
Grape harvesting is a CCP comprising both physical and chemical hazardsPhysically the grapes should be sound without rotten parts otherwise oxidativeand microbial contamination can rapidly develop Therefore harvesting shouldbe conducted with the greatest possible care and an efficient disease managementsystem should be applied (5354) Pesticides play an important role in pest man-agement but they should be handled with care because they constitute chemicalhazards (55) At the time of harvest the grapes must have also reached the correctmaturity when Brix and Total Acidity (TA) levels indicate maturity of wine Sincepesticide and fungicide residues on the surface of the berries constitute chemical
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 21
hazards Oliva et al (56) proposed a rapid and simple gas chromatographic methodfor their determination The maximum residue limits for pesticides in grapes andwines are provided by Codex Alimentarius (45) and Organisation International duVin (57) Finally the bulk bins used for grapes transportation should be effectivelydecontaminated to avoid any microbial infection
Stemming
Stemming includes the removal of stem leaves and grape stalks before crush-ing This procedure has several advantages because the total volume of processedproduct drops by 30 thus resulting in smaller tanks and eventually increasingthe productrsquos alcoholic content (58) However the end of fermentation and the al-cohol content of finished product depend mostly on the Brix level of initial grapesStemmers usually contain a perforated cylinder allowing berries to pass throughbut prevent the passage of stems stalks and leaves
Crushing
Crushing typically immediately follows stemming since some crushing ofthe fruit occurs during stemming The released juice is highly susceptible to oxida-tive browning and microbial contamination The most common crushing processesinvolve pressing the fruit against a perforated wall or passing the fruit through a setof rollers It is very important to avoid crushing the seeds to preclude contaminat-ing the must with seed oils the oxidation of which could produce rancid odors andconstitute an undesirable source of bitter tannins Equally important is the properhandling of product because inappropriate timing might lead to a sudden startof alcoholic fermentation and consequently to higher fermentation temperatureswhile a delay might cause microbial contamination and oxidative browning (59)
Maceration
Maceration is the breakdown of grape solids after crushing of grapes Whilemaceration is always involved in the initial stage of red wine fermentation the long-standing trend has been to limit maceration in white wine production Temperatureand duration of maceration depend on grape and wine variety Usually for white androse wines the maceration time is less than 24 h red destined for early consumptionis macerated for 3ndash5 days and red for aging is macerated from 5 days to 3 weeksFermentation usually occurs during this or at the end of maceration The amount ofthe antimicrobial to be used usually added to white musts that are most sensitive tooxidation depends on the crop health and maceration temperature Sulfur dioxidehas a distinct advantage over other antimicrobial agents because of the relativeinsensitivity of the wine yeasts to its action However it is also toxic or inhibitoryto most bacteria and yeasts (ie Candida Pichia Hansenula) at low concentrations(60) and has a rather low retention capability after the clarification step (61)
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22 KOURTIS AND ARVANITOYANNISTa
ble
3Su
mm
ary
ofH
azar
dsC
CPs
CL
sM
onito
ring
Cor
rect
ive
Act
ions
and
Pers
onne
lRes
pons
ible
for
Sake
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
a(M
CP
)bM
easu
res
CC
PPa
ram
eter
(CL
s)Pr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
CC
ertifi
edsu
pplie
rs
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
wat
er
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Cer
tified
supp
liers
Hea
vym
etal
spr
esen
cein
wat
er
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Eva
luat
ion
ofth
ede
cont
amin
atin
gm
etho
ds
MC
ertifi
edsu
pplie
rs
prop
erpr
epar
atio
n
Mic
robi
alco
ntam
inat
ion
ofth
ecu
lture
100
clea
nM
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Wat
erm
icro
biol
ogic
alqu
ality
Abs
ence
ofpa
thog
ens
Insp
ectio
nof
the
equi
pmen
t
Ric
epo
lishi
ng(C
CP2
)C
Cer
tified
supp
lier
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
polis
hed
rice
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Was
hing
(CC
P3)
PC
ertifi
edsu
pplie
rs
inst
alla
tion
ofau
tom
atic
sepa
rato
r
Ani
mal
impu
ritie
sO
ther
orga
nic
and
inor
gani
cm
ater
01
mm
15
mm
01
mm
Spec
ific
exam
inat
ion
Rew
ashi
ngof
spec
ific
batc
hch
ange
supp
lier
Qua
lity
cont
rol
man
ager
Stea
min
g(f
orun
past
euri
sed
sake
)(C
CP4
)
MG
MP
sche
dule
dm
icro
biol
ogic
alco
ntro
ls
Pres
ence
ofye
asts
and
LA
B
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Spec
ific
batc
hre
proc
essi
ng
CIP
stan
dar-
disa
tion
Qua
lity
cont
rol
man
ager
T
rain
ned
pers
onne
l
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 23
Ferm
enta
tion
(CC
P5)
CM
ater
ialc
ontr
ol
GM
Pco
rros
ion
chec
ks
Hea
vym
etal
pres
ence
Pest
icid
ere
sidu
es
Aslt
02
Cd
lt
001
Pb
lt
03
(mg
L)
Spec
ific
chem
ical
anal
ysis
Dem
etal
lisat
ion
Cha
nge
supp
lier
Rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
GM
Pus
eof
nont
oxic
glyc
ole
Res
idue
sof
ehty
lene
glyc
ole
ampde
terg
ents
0Sp
ecifi
cch
emic
alan
alys
isD
ilutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Alc
ohol
addi
tion
(CC
P6)
CC
ertifi
edsu
pplie
rM
etha
nolc
onte
ntlt
05
gL
GC
exam
inat
ion
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erPa
steu
riza
tion
(CC
P7amp
CC
P8)
MR
unni
ngof
past
euri
ser
acco
rdin
gto
prog
ram
Det
ectio
nof
yeas
tsL
AB
en
zym
atic
activ
ity
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Tem
pera
ture
adju
stm
ent
batc
hre
proc
essi
ng
prop
erm
achi
nery
disi
nfec
tion
Qua
lity
cont
rol
man
ager
Tech
nica
lm
anag
er
aR
egar
ding
the
proc
edur
esof
bottl
ing
stor
age
and
dist
ribu
tion
the
CC
Psar
esi
mila
rto
thos
em
entio
ned
inTa
ble
1fo
rbe
erpr
oduc
tion
bM
CP
stan
dfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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26 KOURTIS AND ARVANITOYANNIS
Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
by [
Sule
yman
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irel
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vers
itesi
] at
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
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ded
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Sule
yman
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irel
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vers
itesi
] at
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ber
2011
ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
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itesi
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 19
Table 2 Quantities of Ingredients at Each Stage of Mixing the Main Mash (Moromi)
Yeast 1st 2nd 3rd 4thStarter (Moto) Addition Addition Addition Additiona Total
Total rice (kg) 210 470 850 1470 3000Steamed rice (kg) 140 330 650 1230 2350Koji rice (kg) 70 140 200 240 65030 Brewerrsquos 1200 1200
alcohol (L)Water (L) 230 420 1010 2030 360 405
aTraditional brewers mix the final mash in three stages The fourth addition of alcohol and wateris a controversial postwar development (Kondo 1984)
components of a number of compounds produced during fermentation (49) Theelevated alcohol content of the fermented sake is related to lipid metabolism ofyeast in the presence of proteolipid provided by the koji molds (5051)
Additions (CCP6)
The addition of alcohol at this stage is carried out unless it is clearly statedthat sake does not contain any alcohol from extraneous sources The added alcoholshould not contain methanol or if it does the content of the latter should be lessthan 05 gL because of its toxicity (CCP chemical hazard)
Pressing
Automatic machine presses (consisting of a series of panels with balloon-likesacks attached) are most widely used nowadays instead of the traditional time-consuming method using long bags The remained caked lees are employed forpickle production and cooking or sedimentation of rice particles may occur Alter-natively sedimentation of rice particles at the bottom of the tank may take place
Filtration
Coloring and aging (maturation) inhibition can be effected by using activatedcharcoal filters
Pasteurization (CCP7 and CCP8)
Heating sake preferably twice at 65C kills off the remaining yeast stops en-zyme action and deactivates the lactic acid bacteria that will eventually spoil sakeThis process represents a microbiological hazard for which the specific plant may
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ORDER REPRINTS
20 KOURTIS AND ARVANITOYANNIS
set CLs However in recent years refrigerated storage and transport have madeunpasteurized sake with characteristic aroma available to the consumer (43)
Dilution
The produced sake in its raw state (Genchu) contains more than 20 alcoholby volume but it is generally diluted to about 15ndash16 vol-
BottlingStorageDistribution
The applied procedures are similar to those mentioned for the beer productionA summary of the occurring hazards CCPs CLs and preventive and correc-
tive measures is given in Table 3
WINE
Introduction
Wines are made from the fruit of Vitis vinifera of which there are a greatnumber of varieties growing in many parts of the world The history of wine isinextricably interwoven with human history It might be as true to say that it waswith wine that civilization began for the vine takes longer to mature than any othercrop and does not produce grapes for wine making until its fourth year It is notexactly known when men first had wine but it was accepted as a gift from the godsthe Egyptians attributed it to Osiris and the Greeks to Dionysos Mesopotamia andthe Caucasian slopes were no doubt early sources of wine from where it was spreadto Egypt and Greece and then to the rest of the world (52)
Wine Main Production Stages
The main stages for wine production are schematically presented in Figure 5
Harvesting (CCP1)
Grape harvesting is a CCP comprising both physical and chemical hazardsPhysically the grapes should be sound without rotten parts otherwise oxidativeand microbial contamination can rapidly develop Therefore harvesting shouldbe conducted with the greatest possible care and an efficient disease managementsystem should be applied (5354) Pesticides play an important role in pest man-agement but they should be handled with care because they constitute chemicalhazards (55) At the time of harvest the grapes must have also reached the correctmaturity when Brix and Total Acidity (TA) levels indicate maturity of wine Sincepesticide and fungicide residues on the surface of the berries constitute chemical
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 21
hazards Oliva et al (56) proposed a rapid and simple gas chromatographic methodfor their determination The maximum residue limits for pesticides in grapes andwines are provided by Codex Alimentarius (45) and Organisation International duVin (57) Finally the bulk bins used for grapes transportation should be effectivelydecontaminated to avoid any microbial infection
Stemming
Stemming includes the removal of stem leaves and grape stalks before crush-ing This procedure has several advantages because the total volume of processedproduct drops by 30 thus resulting in smaller tanks and eventually increasingthe productrsquos alcoholic content (58) However the end of fermentation and the al-cohol content of finished product depend mostly on the Brix level of initial grapesStemmers usually contain a perforated cylinder allowing berries to pass throughbut prevent the passage of stems stalks and leaves
Crushing
Crushing typically immediately follows stemming since some crushing ofthe fruit occurs during stemming The released juice is highly susceptible to oxida-tive browning and microbial contamination The most common crushing processesinvolve pressing the fruit against a perforated wall or passing the fruit through a setof rollers It is very important to avoid crushing the seeds to preclude contaminat-ing the must with seed oils the oxidation of which could produce rancid odors andconstitute an undesirable source of bitter tannins Equally important is the properhandling of product because inappropriate timing might lead to a sudden startof alcoholic fermentation and consequently to higher fermentation temperatureswhile a delay might cause microbial contamination and oxidative browning (59)
Maceration
Maceration is the breakdown of grape solids after crushing of grapes Whilemaceration is always involved in the initial stage of red wine fermentation the long-standing trend has been to limit maceration in white wine production Temperatureand duration of maceration depend on grape and wine variety Usually for white androse wines the maceration time is less than 24 h red destined for early consumptionis macerated for 3ndash5 days and red for aging is macerated from 5 days to 3 weeksFermentation usually occurs during this or at the end of maceration The amount ofthe antimicrobial to be used usually added to white musts that are most sensitive tooxidation depends on the crop health and maceration temperature Sulfur dioxidehas a distinct advantage over other antimicrobial agents because of the relativeinsensitivity of the wine yeasts to its action However it is also toxic or inhibitoryto most bacteria and yeasts (ie Candida Pichia Hansenula) at low concentrations(60) and has a rather low retention capability after the clarification step (61)
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22 KOURTIS AND ARVANITOYANNISTa
ble
3Su
mm
ary
ofH
azar
dsC
CPs
CL
sM
onito
ring
Cor
rect
ive
Act
ions
and
Pers
onne
lRes
pons
ible
for
Sake
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
a(M
CP
)bM
easu
res
CC
PPa
ram
eter
(CL
s)Pr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
CC
ertifi
edsu
pplie
rs
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
wat
er
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Cer
tified
supp
liers
Hea
vym
etal
spr
esen
cein
wat
er
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Eva
luat
ion
ofth
ede
cont
amin
atin
gm
etho
ds
MC
ertifi
edsu
pplie
rs
prop
erpr
epar
atio
n
Mic
robi
alco
ntam
inat
ion
ofth
ecu
lture
100
clea
nM
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Wat
erm
icro
biol
ogic
alqu
ality
Abs
ence
ofpa
thog
ens
Insp
ectio
nof
the
equi
pmen
t
Ric
epo
lishi
ng(C
CP2
)C
Cer
tified
supp
lier
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
polis
hed
rice
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Was
hing
(CC
P3)
PC
ertifi
edsu
pplie
rs
inst
alla
tion
ofau
tom
atic
sepa
rato
r
Ani
mal
impu
ritie
sO
ther
orga
nic
and
inor
gani
cm
ater
01
mm
15
mm
01
mm
Spec
ific
exam
inat
ion
Rew
ashi
ngof
spec
ific
batc
hch
ange
supp
lier
Qua
lity
cont
rol
man
ager
Stea
min
g(f
orun
past
euri
sed
sake
)(C
CP4
)
MG
MP
sche
dule
dm
icro
biol
ogic
alco
ntro
ls
Pres
ence
ofye
asts
and
LA
B
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Spec
ific
batc
hre
proc
essi
ng
CIP
stan
dar-
disa
tion
Qua
lity
cont
rol
man
ager
T
rain
ned
pers
onne
l
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 23
Ferm
enta
tion
(CC
P5)
CM
ater
ialc
ontr
ol
GM
Pco
rros
ion
chec
ks
Hea
vym
etal
pres
ence
Pest
icid
ere
sidu
es
Aslt
02
Cd
lt
001
Pb
lt
03
(mg
L)
Spec
ific
chem
ical
anal
ysis
Dem
etal
lisat
ion
Cha
nge
supp
lier
Rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
GM
Pus
eof
nont
oxic
glyc
ole
Res
idue
sof
ehty
lene
glyc
ole
ampde
terg
ents
0Sp
ecifi
cch
emic
alan
alys
isD
ilutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Alc
ohol
addi
tion
(CC
P6)
CC
ertifi
edsu
pplie
rM
etha
nolc
onte
ntlt
05
gL
GC
exam
inat
ion
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erPa
steu
riza
tion
(CC
P7amp
CC
P8)
MR
unni
ngof
past
euri
ser
acco
rdin
gto
prog
ram
Det
ectio
nof
yeas
tsL
AB
en
zym
atic
activ
ity
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Tem
pera
ture
adju
stm
ent
batc
hre
proc
essi
ng
prop
erm
achi
nery
disi
nfec
tion
Qua
lity
cont
rol
man
ager
Tech
nica
lm
anag
er
aR
egar
ding
the
proc
edur
esof
bottl
ing
stor
age
and
dist
ribu
tion
the
CC
Psar
esi
mila
rto
thos
em
entio
ned
inTa
ble
1fo
rbe
erpr
oduc
tion
bM
CP
stan
dfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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26 KOURTIS AND ARVANITOYANNIS
Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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ORDER REPRINTS
28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
Dow
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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ORDER REPRINTS
34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
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ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
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42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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20 KOURTIS AND ARVANITOYANNIS
set CLs However in recent years refrigerated storage and transport have madeunpasteurized sake with characteristic aroma available to the consumer (43)
Dilution
The produced sake in its raw state (Genchu) contains more than 20 alcoholby volume but it is generally diluted to about 15ndash16 vol-
BottlingStorageDistribution
The applied procedures are similar to those mentioned for the beer productionA summary of the occurring hazards CCPs CLs and preventive and correc-
tive measures is given in Table 3
WINE
Introduction
Wines are made from the fruit of Vitis vinifera of which there are a greatnumber of varieties growing in many parts of the world The history of wine isinextricably interwoven with human history It might be as true to say that it waswith wine that civilization began for the vine takes longer to mature than any othercrop and does not produce grapes for wine making until its fourth year It is notexactly known when men first had wine but it was accepted as a gift from the godsthe Egyptians attributed it to Osiris and the Greeks to Dionysos Mesopotamia andthe Caucasian slopes were no doubt early sources of wine from where it was spreadto Egypt and Greece and then to the rest of the world (52)
Wine Main Production Stages
The main stages for wine production are schematically presented in Figure 5
Harvesting (CCP1)
Grape harvesting is a CCP comprising both physical and chemical hazardsPhysically the grapes should be sound without rotten parts otherwise oxidativeand microbial contamination can rapidly develop Therefore harvesting shouldbe conducted with the greatest possible care and an efficient disease managementsystem should be applied (5354) Pesticides play an important role in pest man-agement but they should be handled with care because they constitute chemicalhazards (55) At the time of harvest the grapes must have also reached the correctmaturity when Brix and Total Acidity (TA) levels indicate maturity of wine Sincepesticide and fungicide residues on the surface of the berries constitute chemical
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 21
hazards Oliva et al (56) proposed a rapid and simple gas chromatographic methodfor their determination The maximum residue limits for pesticides in grapes andwines are provided by Codex Alimentarius (45) and Organisation International duVin (57) Finally the bulk bins used for grapes transportation should be effectivelydecontaminated to avoid any microbial infection
Stemming
Stemming includes the removal of stem leaves and grape stalks before crush-ing This procedure has several advantages because the total volume of processedproduct drops by 30 thus resulting in smaller tanks and eventually increasingthe productrsquos alcoholic content (58) However the end of fermentation and the al-cohol content of finished product depend mostly on the Brix level of initial grapesStemmers usually contain a perforated cylinder allowing berries to pass throughbut prevent the passage of stems stalks and leaves
Crushing
Crushing typically immediately follows stemming since some crushing ofthe fruit occurs during stemming The released juice is highly susceptible to oxida-tive browning and microbial contamination The most common crushing processesinvolve pressing the fruit against a perforated wall or passing the fruit through a setof rollers It is very important to avoid crushing the seeds to preclude contaminat-ing the must with seed oils the oxidation of which could produce rancid odors andconstitute an undesirable source of bitter tannins Equally important is the properhandling of product because inappropriate timing might lead to a sudden startof alcoholic fermentation and consequently to higher fermentation temperatureswhile a delay might cause microbial contamination and oxidative browning (59)
Maceration
Maceration is the breakdown of grape solids after crushing of grapes Whilemaceration is always involved in the initial stage of red wine fermentation the long-standing trend has been to limit maceration in white wine production Temperatureand duration of maceration depend on grape and wine variety Usually for white androse wines the maceration time is less than 24 h red destined for early consumptionis macerated for 3ndash5 days and red for aging is macerated from 5 days to 3 weeksFermentation usually occurs during this or at the end of maceration The amount ofthe antimicrobial to be used usually added to white musts that are most sensitive tooxidation depends on the crop health and maceration temperature Sulfur dioxidehas a distinct advantage over other antimicrobial agents because of the relativeinsensitivity of the wine yeasts to its action However it is also toxic or inhibitoryto most bacteria and yeasts (ie Candida Pichia Hansenula) at low concentrations(60) and has a rather low retention capability after the clarification step (61)
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22 KOURTIS AND ARVANITOYANNISTa
ble
3Su
mm
ary
ofH
azar
dsC
CPs
CL
sM
onito
ring
Cor
rect
ive
Act
ions
and
Pers
onne
lRes
pons
ible
for
Sake
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
a(M
CP
)bM
easu
res
CC
PPa
ram
eter
(CL
s)Pr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
CC
ertifi
edsu
pplie
rs
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
wat
er
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Cer
tified
supp
liers
Hea
vym
etal
spr
esen
cein
wat
er
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Eva
luat
ion
ofth
ede
cont
amin
atin
gm
etho
ds
MC
ertifi
edsu
pplie
rs
prop
erpr
epar
atio
n
Mic
robi
alco
ntam
inat
ion
ofth
ecu
lture
100
clea
nM
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Wat
erm
icro
biol
ogic
alqu
ality
Abs
ence
ofpa
thog
ens
Insp
ectio
nof
the
equi
pmen
t
Ric
epo
lishi
ng(C
CP2
)C
Cer
tified
supp
lier
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
polis
hed
rice
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Was
hing
(CC
P3)
PC
ertifi
edsu
pplie
rs
inst
alla
tion
ofau
tom
atic
sepa
rato
r
Ani
mal
impu
ritie
sO
ther
orga
nic
and
inor
gani
cm
ater
01
mm
15
mm
01
mm
Spec
ific
exam
inat
ion
Rew
ashi
ngof
spec
ific
batc
hch
ange
supp
lier
Qua
lity
cont
rol
man
ager
Stea
min
g(f
orun
past
euri
sed
sake
)(C
CP4
)
MG
MP
sche
dule
dm
icro
biol
ogic
alco
ntro
ls
Pres
ence
ofye
asts
and
LA
B
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Spec
ific
batc
hre
proc
essi
ng
CIP
stan
dar-
disa
tion
Qua
lity
cont
rol
man
ager
T
rain
ned
pers
onne
l
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 23
Ferm
enta
tion
(CC
P5)
CM
ater
ialc
ontr
ol
GM
Pco
rros
ion
chec
ks
Hea
vym
etal
pres
ence
Pest
icid
ere
sidu
es
Aslt
02
Cd
lt
001
Pb
lt
03
(mg
L)
Spec
ific
chem
ical
anal
ysis
Dem
etal
lisat
ion
Cha
nge
supp
lier
Rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
GM
Pus
eof
nont
oxic
glyc
ole
Res
idue
sof
ehty
lene
glyc
ole
ampde
terg
ents
0Sp
ecifi
cch
emic
alan
alys
isD
ilutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Alc
ohol
addi
tion
(CC
P6)
CC
ertifi
edsu
pplie
rM
etha
nolc
onte
ntlt
05
gL
GC
exam
inat
ion
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erPa
steu
riza
tion
(CC
P7amp
CC
P8)
MR
unni
ngof
past
euri
ser
acco
rdin
gto
prog
ram
Det
ectio
nof
yeas
tsL
AB
en
zym
atic
activ
ity
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Tem
pera
ture
adju
stm
ent
batc
hre
proc
essi
ng
prop
erm
achi
nery
disi
nfec
tion
Qua
lity
cont
rol
man
ager
Tech
nica
lm
anag
er
aR
egar
ding
the
proc
edur
esof
bottl
ing
stor
age
and
dist
ribu
tion
the
CC
Psar
esi
mila
rto
thos
em
entio
ned
inTa
ble
1fo
rbe
erpr
oduc
tion
bM
CP
stan
dfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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26 KOURTIS AND ARVANITOYANNIS
Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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ORDER REPRINTS
34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
by [
Sule
yman
Dem
irel
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vers
itesi
] at
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ber
2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
nloa
ded
by [
Sule
yman
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irel
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vers
itesi
] at
09
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ber
2011
ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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irel
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itesi
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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ded
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yman
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irel
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itesi
] at
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ber
2011
ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
Dow
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ded
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yman
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irel
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itesi
] at
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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ded
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ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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ded
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yman
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irel
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itesi
] at
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ber
2011
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 21
hazards Oliva et al (56) proposed a rapid and simple gas chromatographic methodfor their determination The maximum residue limits for pesticides in grapes andwines are provided by Codex Alimentarius (45) and Organisation International duVin (57) Finally the bulk bins used for grapes transportation should be effectivelydecontaminated to avoid any microbial infection
Stemming
Stemming includes the removal of stem leaves and grape stalks before crush-ing This procedure has several advantages because the total volume of processedproduct drops by 30 thus resulting in smaller tanks and eventually increasingthe productrsquos alcoholic content (58) However the end of fermentation and the al-cohol content of finished product depend mostly on the Brix level of initial grapesStemmers usually contain a perforated cylinder allowing berries to pass throughbut prevent the passage of stems stalks and leaves
Crushing
Crushing typically immediately follows stemming since some crushing ofthe fruit occurs during stemming The released juice is highly susceptible to oxida-tive browning and microbial contamination The most common crushing processesinvolve pressing the fruit against a perforated wall or passing the fruit through a setof rollers It is very important to avoid crushing the seeds to preclude contaminat-ing the must with seed oils the oxidation of which could produce rancid odors andconstitute an undesirable source of bitter tannins Equally important is the properhandling of product because inappropriate timing might lead to a sudden startof alcoholic fermentation and consequently to higher fermentation temperatureswhile a delay might cause microbial contamination and oxidative browning (59)
Maceration
Maceration is the breakdown of grape solids after crushing of grapes Whilemaceration is always involved in the initial stage of red wine fermentation the long-standing trend has been to limit maceration in white wine production Temperatureand duration of maceration depend on grape and wine variety Usually for white androse wines the maceration time is less than 24 h red destined for early consumptionis macerated for 3ndash5 days and red for aging is macerated from 5 days to 3 weeksFermentation usually occurs during this or at the end of maceration The amount ofthe antimicrobial to be used usually added to white musts that are most sensitive tooxidation depends on the crop health and maceration temperature Sulfur dioxidehas a distinct advantage over other antimicrobial agents because of the relativeinsensitivity of the wine yeasts to its action However it is also toxic or inhibitoryto most bacteria and yeasts (ie Candida Pichia Hansenula) at low concentrations(60) and has a rather low retention capability after the clarification step (61)
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22 KOURTIS AND ARVANITOYANNISTa
ble
3Su
mm
ary
ofH
azar
dsC
CPs
CL
sM
onito
ring
Cor
rect
ive
Act
ions
and
Pers
onne
lRes
pons
ible
for
Sake
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
a(M
CP
)bM
easu
res
CC
PPa
ram
eter
(CL
s)Pr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
CC
ertifi
edsu
pplie
rs
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
wat
er
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Cer
tified
supp
liers
Hea
vym
etal
spr
esen
cein
wat
er
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Eva
luat
ion
ofth
ede
cont
amin
atin
gm
etho
ds
MC
ertifi
edsu
pplie
rs
prop
erpr
epar
atio
n
Mic
robi
alco
ntam
inat
ion
ofth
ecu
lture
100
clea
nM
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Wat
erm
icro
biol
ogic
alqu
ality
Abs
ence
ofpa
thog
ens
Insp
ectio
nof
the
equi
pmen
t
Ric
epo
lishi
ng(C
CP2
)C
Cer
tified
supp
lier
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
polis
hed
rice
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Was
hing
(CC
P3)
PC
ertifi
edsu
pplie
rs
inst
alla
tion
ofau
tom
atic
sepa
rato
r
Ani
mal
impu
ritie
sO
ther
orga
nic
and
inor
gani
cm
ater
01
mm
15
mm
01
mm
Spec
ific
exam
inat
ion
Rew
ashi
ngof
spec
ific
batc
hch
ange
supp
lier
Qua
lity
cont
rol
man
ager
Stea
min
g(f
orun
past
euri
sed
sake
)(C
CP4
)
MG
MP
sche
dule
dm
icro
biol
ogic
alco
ntro
ls
Pres
ence
ofye
asts
and
LA
B
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Spec
ific
batc
hre
proc
essi
ng
CIP
stan
dar-
disa
tion
Qua
lity
cont
rol
man
ager
T
rain
ned
pers
onne
l
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 23
Ferm
enta
tion
(CC
P5)
CM
ater
ialc
ontr
ol
GM
Pco
rros
ion
chec
ks
Hea
vym
etal
pres
ence
Pest
icid
ere
sidu
es
Aslt
02
Cd
lt
001
Pb
lt
03
(mg
L)
Spec
ific
chem
ical
anal
ysis
Dem
etal
lisat
ion
Cha
nge
supp
lier
Rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
GM
Pus
eof
nont
oxic
glyc
ole
Res
idue
sof
ehty
lene
glyc
ole
ampde
terg
ents
0Sp
ecifi
cch
emic
alan
alys
isD
ilutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Alc
ohol
addi
tion
(CC
P6)
CC
ertifi
edsu
pplie
rM
etha
nolc
onte
ntlt
05
gL
GC
exam
inat
ion
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erPa
steu
riza
tion
(CC
P7amp
CC
P8)
MR
unni
ngof
past
euri
ser
acco
rdin
gto
prog
ram
Det
ectio
nof
yeas
tsL
AB
en
zym
atic
activ
ity
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Tem
pera
ture
adju
stm
ent
batc
hre
proc
essi
ng
prop
erm
achi
nery
disi
nfec
tion
Qua
lity
cont
rol
man
ager
Tech
nica
lm
anag
er
aR
egar
ding
the
proc
edur
esof
bottl
ing
stor
age
and
dist
ribu
tion
the
CC
Psar
esi
mila
rto
thos
em
entio
ned
inTa
ble
1fo
rbe
erpr
oduc
tion
bM
CP
stan
dfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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26 KOURTIS AND ARVANITOYANNIS
Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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ORDER REPRINTS
28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
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ded
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] at
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
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ded
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ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
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42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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22 KOURTIS AND ARVANITOYANNISTa
ble
3Su
mm
ary
ofH
azar
dsC
CPs
CL
sM
onito
ring
Cor
rect
ive
Act
ions
and
Pers
onne
lRes
pons
ible
for
Sake
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
a(M
CP
)bM
easu
res
CC
PPa
ram
eter
(CL
s)Pr
oced
ures
Act
ions
Pers
onne
l
Inco
min
gra
wm
ater
ials
(CC
P1)
CC
ertifi
edsu
pplie
rs
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
wat
er
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Cer
tified
supp
liers
Hea
vym
etal
spr
esen
cein
wat
er
With
insp
ecifi
catio
nspr
escr
ibed
inD
irec
tive
807
78E
C
Eva
luat
ion
ofth
ede
cont
amin
atin
gm
etho
ds
MC
ertifi
edsu
pplie
rs
prop
erpr
epar
atio
n
Mic
robi
alco
ntam
inat
ion
ofth
ecu
lture
100
clea
nM
icro
biol
ogic
alan
alys
isR
ejec
tion
ofsp
ecifi
cba
tch
Qua
lity
cont
rol
man
ager
Prop
erw
ater
deco
ntam
inat
ion
Wat
erm
icro
biol
ogic
alqu
ality
Abs
ence
ofpa
thog
ens
Insp
ectio
nof
the
equi
pmen
t
Ric
epo
lishi
ng(C
CP2
)C
Cer
tified
supp
lier
effic
ient
dise
ase
man
agem
ent
syst
emin
use
Pest
icid
ere
sidu
esin
polis
hed
rice
MR
Ls
asde
scri
bed
byC
odex
Alim
enta
rius
Spec
ific
chem
ical
anal
ysis
Rej
ectio
nof
spec
ific
batc
hC
hang
esu
pplie
r
Qua
lity
cont
rol
man
ager
Was
hing
(CC
P3)
PC
ertifi
edsu
pplie
rs
inst
alla
tion
ofau
tom
atic
sepa
rato
r
Ani
mal
impu
ritie
sO
ther
orga
nic
and
inor
gani
cm
ater
01
mm
15
mm
01
mm
Spec
ific
exam
inat
ion
Rew
ashi
ngof
spec
ific
batc
hch
ange
supp
lier
Qua
lity
cont
rol
man
ager
Stea
min
g(f
orun
past
euri
sed
sake
)(C
CP4
)
MG
MP
sche
dule
dm
icro
biol
ogic
alco
ntro
ls
Pres
ence
ofye
asts
and
LA
B
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Spec
ific
batc
hre
proc
essi
ng
CIP
stan
dar-
disa
tion
Qua
lity
cont
rol
man
ager
T
rain
ned
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 23
Ferm
enta
tion
(CC
P5)
CM
ater
ialc
ontr
ol
GM
Pco
rros
ion
chec
ks
Hea
vym
etal
pres
ence
Pest
icid
ere
sidu
es
Aslt
02
Cd
lt
001
Pb
lt
03
(mg
L)
Spec
ific
chem
ical
anal
ysis
Dem
etal
lisat
ion
Cha
nge
supp
lier
Rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
GM
Pus
eof
nont
oxic
glyc
ole
Res
idue
sof
ehty
lene
glyc
ole
ampde
terg
ents
0Sp
ecifi
cch
emic
alan
alys
isD
ilutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Alc
ohol
addi
tion
(CC
P6)
CC
ertifi
edsu
pplie
rM
etha
nolc
onte
ntlt
05
gL
GC
exam
inat
ion
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erPa
steu
riza
tion
(CC
P7amp
CC
P8)
MR
unni
ngof
past
euri
ser
acco
rdin
gto
prog
ram
Det
ectio
nof
yeas
tsL
AB
en
zym
atic
activ
ity
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Tem
pera
ture
adju
stm
ent
batc
hre
proc
essi
ng
prop
erm
achi
nery
disi
nfec
tion
Qua
lity
cont
rol
man
ager
Tech
nica
lm
anag
er
aR
egar
ding
the
proc
edur
esof
bottl
ing
stor
age
and
dist
ribu
tion
the
CC
Psar
esi
mila
rto
thos
em
entio
ned
inTa
ble
1fo
rbe
erpr
oduc
tion
bM
CP
stan
dfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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ORDER REPRINTS
26 KOURTIS AND ARVANITOYANNIS
Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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ORDER REPRINTS
28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
by [
Sule
yman
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irel
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vers
itesi
] at
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
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ber
2011
ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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yman
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irel
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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yman
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irel
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itesi
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2011
ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
Dow
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irel
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itesi
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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] at
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2011
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 23
Ferm
enta
tion
(CC
P5)
CM
ater
ialc
ontr
ol
GM
Pco
rros
ion
chec
ks
Hea
vym
etal
pres
ence
Pest
icid
ere
sidu
es
Aslt
02
Cd
lt
001
Pb
lt
03
(mg
L)
Spec
ific
chem
ical
anal
ysis
Dem
etal
lisat
ion
Cha
nge
supp
lier
Rej
ectio
nof
spec
ific
batc
h
Qua
lity
cont
rol
man
ager
GM
Pus
eof
nont
oxic
glyc
ole
Res
idue
sof
ehty
lene
glyc
ole
ampde
terg
ents
0Sp
ecifi
cch
emic
alan
alys
isD
ilutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Alc
ohol
addi
tion
(CC
P6)
CC
ertifi
edsu
pplie
rM
etha
nolc
onte
ntlt
05
gL
GC
exam
inat
ion
Rej
ectio
nof
spec
ific
batc
hQ
ualit
yco
ntro
lm
anag
erPa
steu
riza
tion
(CC
P7amp
CC
P8)
MR
unni
ngof
past
euri
ser
acco
rdin
gto
prog
ram
Det
ectio
nof
yeas
tsL
AB
en
zym
atic
activ
ity
Setb
yth
esp
ecifi
cpl
ant
Mic
robi
olog
ical
anal
ysis
Tem
pera
ture
adju
stm
ent
batc
hre
proc
essi
ng
prop
erm
achi
nery
disi
nfec
tion
Qua
lity
cont
rol
man
ager
Tech
nica
lm
anag
er
aR
egar
ding
the
proc
edur
esof
bottl
ing
stor
age
and
dist
ribu
tion
the
CC
Psar
esi
mila
rto
thos
em
entio
ned
inTa
ble
1fo
rbe
erpr
oduc
tion
bM
CP
stan
dfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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2011
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24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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26 KOURTIS AND ARVANITOYANNIS
Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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ORDER REPRINTS
34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
by [
Sule
yman
Dem
irel
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vers
itesi
] at
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ber
2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
nloa
ded
by [
Sule
yman
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irel
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vers
itesi
] at
09
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ber
2011
ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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irel
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itesi
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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ded
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yman
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irel
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itesi
] at
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ber
2011
ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
Dow
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ded
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yman
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irel
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itesi
] at
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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ded
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ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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ded
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yman
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irel
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itesi
] at
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ber
2011
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24 KOURTIS AND ARVANITOYANNIS
Figure 5 Process flow diagram of wine production (355258)
Pressing
The must is allowed to remain in the press for several minutes during whichjuice runs out under its own weight Depending on the press type (horizontalpneumatic continuous screw presses) the produced juice and wine fractions varyin terms of their physicochemical properties Combining different wine fractionsthe winemaker can influence the character of the wine However a potential hazardmight be the occurrence of oxidation reactions if there is a delay in the process(52)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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26 KOURTIS AND ARVANITOYANNIS
Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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ORDER REPRINTS
34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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2011
ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
by [
Sule
yman
Dem
irel
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vers
itesi
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
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ecem
ber
2011
ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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irel
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itesi
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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ded
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yman
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irel
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itesi
] at
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ecem
ber
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
Dow
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ded
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yman
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irel
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vers
itesi
] at
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 25
Alcoholic Fermentation (CCP2)
Alcoholic fermentation is usually carried out by strains of Saccharomycescerevisiae because this species is remarkably tolerant to high sugar ethanol andsulfur dioxide concentrations and also grows at low pH values typical for grapemust (pH 32ndash4) The culture of Saccharomyces cerevisiae is either part of theindigenous microflora or may be partially added to achieve a population of about105 to 106 cellsml in the must (CCP3 microbiological hazard) (62) Possiblecontamination of must with killer yeasts (a property mainly present in wild strainsof Saccharomyces but also in other yeast genera such as Candida DebaryomycesHansenula Kluyveromyces Pichia Torulopsis and Cryptococcus) may result instuck fermentation (63) Attention should be paid to the added amount of sulfurdioxide (total SO2 175 and 225 mgL for red and white wine respectively) inorder to inhibit if not to kill most of the indigenous yeast population of grapes(64) as well as acidity adjustment and to sugar and tannin concentration of thejuice
In fermentation the encountered chemical hazards consist of heavy metalspresence (As lt 02 Cd lt 001 Cu lt 1 Pb lt 03 mgL) methanol content (300 and150 mgL for red and white wine respectively) ethyl carbamate content pesticideresidues (as mentioned in the Codex Alimentarius) and residues of detergents (ab-sence) and ethylene glycol (absence) CLs may be established and monitored withspecific chemical analyses Special attention should be paid regarding the ethyl car-bamate content because there is no legislative action against it in Europe contraryto the United States (lt15 ppb and lt60 ppb for table and desert wines respec-tively) and Canada (30 ppb and 100 ppb for table and desert wines respectively)The latter is formed from reaction of alcohols with substances rich in nitrogenouscompounds mainly urea and aminoacids like arginine and citruline Its control iscarried out with gas chromatography and its prevention can be accomplished byavoiding intensive organic fertilization of vines high temperatures at the end orafter the alcoholic fermentation using yeast cultures tested for low urea and ethylcarbamate production employing urease and determining urea when long storageis intended and carried out The fermentation temperature is one of the most crucialfactors affecting yeast metabolism both directly and indirectly For white and redwines the desirable temperature varies within the range of 8ndash15C and 25ndash28Crespectively Any presence of residual sugars (ie sucrose glucose fructose) by theend of fermentation is a hazard that might cause microbial destabilization of wineThe fermentation process requires no oxygen Nevertheless traces of oxygen atthe beginning of the exponential phase of yeast growth speed up the fermentationbecause the yeast population increases and the average cell viability prolongedThe pH might affect the process only at extreme values (lt30) where the growthof fermentative yeasts is inhibited (59)
Finally the fungicide residues in the must might play an inhibitory role inthe yeastrsquos growth and undermine the sensory qualities of the wine by affectingbiosynthetic pathways (65ndash67)
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26 KOURTIS AND ARVANITOYANNIS
Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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ORDER REPRINTS
28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
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yman
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irel
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
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ded
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yman
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irel
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ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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ded
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irel
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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26 KOURTIS AND ARVANITOYANNIS
Malolactic Fermentation
Early onset and completion of malolactic fermentation allows the prompt addi-tion of sulfur dioxide storage at cool temperatures and clarification It is conductedby lactic acid bacteria (Oennococcus oenos) which directly decarboxylate L-malicacid (dicarboxylic acid) to L-lactic acid (monocarboxylic acid) This metabolismresults in acidity reduction and pH increase which are in turn related to an in-creased smoothness and drinkability of red wines but might also generate a flattaste (6869) The initial pH the sulfite concentration (70) the phenolics and theanthocyanin content (71) of juicewine strongly affect whether when and how(with what species) malolactic fermentation will occur Bacterial viruses (phages)can severely disrupt malolactic fermentation by attacking the Oennococcus oenoscells thus causing microbial destabilization of wine (72) Therefore to assure thedevelopment of malolactic fermentation winemakers inoculate the wine with oneor more strains of Oennococcus oenos (CCP3) (7374) After fermentation thewinersquos desirable total acidity is generally considered to vary within the range of055ndash085 (white and red wines toward the upper and lower end respectively)Whenever the total acidity surpasses those limits acidification and deacidificationtechniques should be in place (35)
Maturation (CCP4)
The maturation step often lasts 6ndash24 months and takes place in oak barrelsDuring maturation a range of physical and chemical interactions occurs among thebarrel the surrounding atmosphere and the maturing wine leading to transforma-tion of flavor and composition of wine (75) Here there is a CCP concerning the oakbarrel which should be fault-free and should have undergone a decontaminationtreatment The wood also must be free of pronounced or undesirable odors whichcould taint the wine (76) During the maturation period several components of thewood (most of them phenolics) are extracted to the wine tannin (7778) Since oaktannins can significantly add to the bitter taste of wine white wines are usually ma-tured in oak for shorter periods than red wines and in conditioned barrels to releaseless extractable (7980) Another CCP is related to the inhibition of the oxygen pen-etration through wood or during racking and sampling of wine Although a slightoxidation is desirable a more extensive one can cause various sensory changes suchas oxidized odor browning loss of color in red wines activation of spoilage bacte-ria and yeasts development of ferric casse and precipitation of tannins (81) Limitson free and total SO2 levels in finished wine are variable from country to country
Clarification
Clarification involves only physical means of removing the suspended par-ticulate matter Juice clarification by racking centrifugation or filtration often
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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ORDER REPRINTS
28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
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yman
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irel
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
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ded
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yman
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irel
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ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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ded
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irel
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 27
improves the flavor development in white wine and helps the prevention of micro-bial spoilage If sufficient time is provided racking and fining can produce stablecrystal clear wines but now that early bottling in a few weeks or months after fer-mentation is employed centrifugation and filtration are used to obtain the requiredclarity level (82) Microbial contamination of wine during the above mentionedprocedures constitutes a potential problem for its stability (83) Racking is alsoeffective on pesticide residue reduction of wine (84)
Stabilization (CCP5)
The reason for stabilization is production of a permanently clear and flavorfault-free wine The most important procedures include a) tartrate stabilizationby chilling the wine to near its freezing point and then filtering or centrifugingto remove the crystals b) protein stabilization with absorption denaturation orneutralization by fining agents (bentonite) (85) c) polysaccharide removal withpectinases that hydrolyze the polymer disturbing its protective colloidal actionand filter plugging properties (82) and d) metal casse (Fe Cu) stabilization Fer-ric casse is controlled by the addition of agents (bentonites proteins) controllingthe flocculation of insoluble ferric complexes whereas wines with copper contentgreater than 05 mgL are particularly susceptible to copper casse formation (86)Legal residual copper levels in finished wines are variable and not all methods forcopper removal are approved in all countries In particular all wine industry federalregulations for the US industry can be accessed via the Bureau of Alcohol Tobaccoand Firearms (BATF) (available at httpwwwatftreasgov)
Bottling (CCP6)
Wine is bottled in glass bottles sealed with cork The bottles must pass adecontaminating step and an inspection control to assure the absence of any de-fects and the stability of the product until its consumption (87) The cork shouldbe correctly sized 6ndash7 mm bigger than the inner neck diameter to avoid any pos-sible leaks In bottling all three hazards may be encountered In particular corkmicroflora residues of heavy metals SO2 pesticides and detergents and absenceof cracks scratches and rifts in the lute represent microbiological chemical andphysical hazards Although cork is noted for its chemical inertness in contact withwine it might cause off-flavors when contaminated (8889) or when the produc-ers are not applying effective quality control (90) The CL for cork is absence ofLAB and yeast which can be assured with microbiological analysis When longstorage of wine is anticipated longer and denser corks are preferred because pro-longed exposure slowly affects the cork integrity Since on compression a plungerforces the cork down into the neck of the bottle precaution must be taken against thebuildup of microbes within the equipment (9183) the lead transfer to wine through
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ORDER REPRINTS
28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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ORDER REPRINTS
34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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2011
ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
by [
Sule
yman
Dem
irel
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vers
itesi
] at
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
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ecem
ber
2011
ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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irel
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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ded
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yman
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irel
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itesi
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ecem
ber
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
Dow
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ded
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yman
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irel
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vers
itesi
] at
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
Dow
nloa
ded
by [
Sule
yman
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irel
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vers
itesi
] at
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44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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28 KOURTIS AND ARVANITOYANNIS
the wine-cork-capsule system (92) and the oxidation during filling by flushing thebottles with carbon dioxide Cork insertion may also occur under vacuum Theheadspace oxygen might affect the product quality by causing the disease ofthe ldquobottlerdquo The CL for SO2 is 175 and 225 mgL for red and white wine re-spectively for As lt 02 mgL Cd lt 001 mgL Cu lt 1 mgL Pb lt 03 mgL theresidues of pesticides and insecticides in the final product are provided by OfficeInternational de la Vigne et du Vin (57)
Storage (CCP7)
Shipping and storage of wines at elevated temperatures can initiate rapidchanges in color and flavor of wine Direct exposure to sunlight corresponds to theeffect of warm storage temperatures Temperature affects reaction rates involvedin the maturation such as the acceleration of hydrolysis of aromatic esters andthe loss of terpene fragrances (93) Temperature can also affect the wine volumeand eventually loosen the cork seal leading to leakage oxidation and possiblymicrobial formation resulting in spoilage of bottled wine
The occurring hazards CCPs CLs preventive and corrective measures aregiven synoptically in Table 4
DISTILLED SPIRITS
Introduction
Distillation is one of the earliest examples of implementation of chemicaltechnology The process was known in China many hundred years before the birthof Christ and the first distilled beverage is believed to have been made from riceabout 800 BC The first few years AD the Arabs learned the technology and fromthem distillation was introduced to Western Europe (25) The spirit distillation in-dustry comprises a heterogeneous assortment of manufacturing processes linked byyeasts as a common function Distillery spirits are available in many forms varyingfrom pure alcohol to complex potable spirits Nevertheless they are all based on thesame biochemical and physical principles and similar manufacturing stages (18)Gin and vodka typify non-cogeneric spirits In the case of gin the spirit is flavoredwith juniper and other ldquobotanicalsrdquo while with vodka the flavor is modified byfiltration through charcoal Both distillates can be produced from the several grainsor potatoes fermentation depending essentially on consistency and reliability ofsupply and quality and on economics and on the plant available (13) Ouzo themost popular distilled spirit consumed in Greece is traditionally manufacturedfrom wine distillation Its characteristic aroma and flavor are attributed to anetholthe main constituent of anise seed (94) Brandy is a spirit distilled from wine andis produced in all viticultural regions In terms of quality the best-known brandiesare Cognac and Armagnac Both of these brandies are produced by distillation ofwhite wine from geographically defined regions of France
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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ORDER REPRINTS
34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
by [
Sule
yman
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irel
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vers
itesi
] at
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
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ber
2011
ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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yman
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irel
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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ded
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yman
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irel
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itesi
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2011
ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
Dow
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ded
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yman
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irel
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itesi
] at
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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yman
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irel
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] at
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ecem
ber
2011
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 29
Tabl
e4
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rW
ine
Prod
uctio
n
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Har
vest
ing
(CC
P1)
PC
aref
ulha
ndlin
gof
grap
esSo
und
frui
twith
out
rotte
npa
rts
Red
uced
toac
cept
able
leve
lIn
spec
tion
duri
ngha
rves
ting
Inst
ruct
pers
onne
lT
rain
edpe
rson
nel
CSp
ecif
yth
ela
stda
yof
appl
ying
pest
icid
es
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Spec
ific
chem
ical
anal
yses
Del
ayof
harv
estin
gda
te
Qua
lity
cont
rol
man
ager
Ferm
enta
tion
(CC
P2)
CM
ater
ialw
ithou
the
avy
met
als
corr
osio
nch
ecks
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esPe
rpe
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
Car
eful
mai
ntai
nth
eeq
uipm
ent
use
ofno
n-to
xic
gluc
ole
GM
P
Res
idue
sof
ethy
lene
glyc
ole
ampde
terg
ents
Met
hano
lco
nten
t
Abs
ence
300
mg
L(r
ed)
150
mg
L(w
hite
ampro
se)
Rej
ectio
nof
spec
ific
batc
hdi
lutio
nw
ithla
rge
quan
titie
sm
achi
nery
mod
ifica
tion
Avo
idin
tens
ive
fert
iliza
tion
Avo
idhi
ghte
mpe
ratu
res
Use
prop
erye
ast
cultu
res
Em
ploy
urea
se
Eth
ylca
rbam
ate
form
atio
nlt
15(3
0)an
dlt
60(1
00)
ppb
for
tabl
ean
dde
sert
win
esin
USA
(Can
ada)
re
spec
tivel
y
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Bac
teri
alpr
epar
atio
ns(C
CP3
)
MC
ertifi
edsu
pplie
rs
stri
ctly
follo
win
gin
stru
ctio
ns
Mic
robi
olog
ical
cont
amin
atio
n10
0cl
ean
Mic
robi
olog
ical
anal
yses
Cha
nge
supp
lier
orm
etho
dof
prep
arat
ion
Qua
lity
cont
rol
man
ager
(con
tinu
ed)
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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ORDER REPRINTS
34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
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ded
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
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ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
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ded
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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ORDER REPRINTS
30 KOURTIS AND ARVANITOYANNIS
Tabl
e4
Con
tinu
ed
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(CM
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Mat
urat
ion
(CC
P4)
MC
ertifi
edsu
pplie
rs
prop
erba
rrel
deco
ntam
inat
ion
Mic
robi
olog
ical
cont
amin
atio
nA
bsen
ceof
yeas
ts
mol
dsan
dla
ctic
acid
bact
eria
Mic
robi
olog
ical
anal
yses
Rew
ash
the
barr
elQ
ualit
yco
ntro
lm
anag
erSt
abili
zatio
n(C
CP5
)C
GM
Pm
ater
ials
with
outh
eavy
met
als
calc
ulat
ion
of
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
ferr
ocyo
nide
need
edac
cord
ing
toFe
pres
ent
Res
idua
lfe
rroc
yoni
deFe
5m
gL
Filtr
atio
nor
dilu
tion
with
larg
erqu
antit
ies
Qua
lity
cont
rol
man
ager
Bot
tling
(CC
P6)
CG
MP
mat
eria
lsw
ithou
thea
vym
etal
s
Hea
vym
etal
spr
esen
ceA
slt
02
Cd
lt
001
Cu
lt1
Pblt
03
(mg
L)
Spec
ific
chem
ical
anal
yses
Rej
ectio
nof
spec
ific
batc
hde
met
allis
atio
n
Qua
lity
cont
rol
man
ager
Cer
tified
supp
liers
co
ntro
lof
the
prod
uct
Pest
icid
ere
sidu
esB
ype
stic
ide
acco
rdin
gto
Cod
exA
lim
Rej
ectio
nof
spec
ific
batc
h
GM
Pav
oida
nce
ofhi
ghdo
ses
Det
erge
ntan
dSO
2re
sidu
esN
one
175
mg
L(r
ed)
225
mg
L(w
hite
ros
e)
Mod
ifica
tion
ofth
eC
IPr
ejec
tion
ofba
tch
BIn
spec
tion
and
scre
enin
gof
the
bottl
ing
area
Inse
ctpr
esen
cein
the
full
bottl
es
Non
eV
isua
lins
pect
ion
Dis
infe
ctth
ear
ear
ejec
tion
ofsp
ecifi
cba
tch
Tra
ined
pers
onne
l
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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ORDER REPRINTS
34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
by [
Sule
yman
Dem
irel
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vers
itesi
] at
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ber
2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
nloa
ded
by [
Sule
yman
Dem
irel
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vers
itesi
] at
09
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ber
2011
ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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irel
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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ded
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yman
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irel
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itesi
] at
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
Dow
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ded
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yman
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irel
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itesi
] at
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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yman
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irel
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] at
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ber
2011
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 31
PC
ertifi
edsu
pplie
rco
ntin
uous
insp
ectio
n
Bot
tleco
nditi
onA
bsen
ceof
rift
sin
the
lute
cra
cks
scra
tche
s
On-
line
visu
alin
spec
tion
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Cer
tified
supp
lier
Cor
ksi
zing
Prop
ortio
nalt
oth
ebo
ttle
Sam
ple
mea
sure
men
tsM
Cer
tified
supp
lier
esta
blis
hmen
tof
deco
ntam
inat
ion
proc
esse
s
Cor
km
icro
flora
Yea
stL
AB
abse
nce
Mic
robi
olog
ical
anal
yses
Rej
ectio
nof
faul
tyco
rks
deco
ntam
inat
ion
proc
ess
Qua
lity
cont
rol
man
ager
Stor
age
(CC
P7)
PC
ontr
olst
orag
eco
nditi
ons
and
reta
ilst
ores
Win
equ
ality
Setb
yea
chpl
ant
Org
anol
eptic
cont
rols
Rej
ectio
nof
faul
tyba
tche
sT
rain
edpe
rson
nel
aC
MP
sym
bols
stan
dsfo
rch
emic
alm
icro
biol
ogic
alan
dph
ysic
alha
zard
sre
spec
tivel
y
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ORDER REPRINTS
32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
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ded
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irel
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] at
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ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
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42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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32 KOURTIS AND ARVANITOYANNIS
Distilled Spirits Main Production Stages
The main stages for the production of the above mentioned distilled spiritsare shown schematically in Figure 6
Figure 6 Process flow diagram of distilled spirits production (2597)
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
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irel
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itesi
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ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
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itesi
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 33
Incoming Raw Materials (CCP1)
Incoming raw materials such as alcohol aromatic seeds (anise) sucrose andglass bottles reach the corresponding department of the factory in large containersAll materials are purchased against specifications agreed with the certified supplierswho are inspected reviewed and assessed annually on basis of quality and avail-ability of their raw materials The wine used for ouzo and brandy production shouldcomply with parameters of the finished products mentioned in Table 4 Alcohol isusually delivered in batches by large tankers consisting of one two or three separatetanks Alcohol must be of at least 96 vol- alcohol free of volatile compounds thatmay affect the aroma of anise (Pimpinella anisum) having a methanol concentra-tion lower than 05 gL Qualitative and quantitative measurements of each alcoholsample are taken by gas chromatography (GC) The grains should comply withpesticide and heavy metal residues set by Codex Alimentarius and national legis-lation and they should also be mycotoxin-free as earlier mentioned in the brewingsection Flavourful seeds are sampled and undergo microbiological and chemicalanalysis for E coli B cereus Cl perfrigens and toxic metals as As Cd Hg Micro-biological control is based on prescribed instructions including visual examinationfor undesirable mold or any other bacterial development and count after incuba-tion of Escherichia coli (CCL = 103 cfug) Bacillus cereus (CCL = 104 cfug) andClostridium perfrigens (CCL = 103 cfug) Chemical control includes toxicolog-ical analyses for high concentration levels of toxic or heavy metals such as As(CCL = 10 mgkg) Cd (CCL = 1 mgkg) and Hg (CCL = 1 mgkg) as well as thecongealing and melting point of the essential oil anise (95) Other quality controltests could comprise specific gravity tests refractive index optical rotation andsolubility in alcohol (96) Anethol the main component of anise should also un-dergo chemical analysis by GC to ensure that its concentration in cis-anethol (toxicisomer) lies below 1
Cooking
This stage concerns solely the gin and vodka production from grains or pota-toes Cooking is required for maize and other cereals as well as for potatoes Batchor continuous cookers can be used and premalting is common practice Malt istraditionally used for the conversion of starch to sugars but has no role in fla-vor Continuous cooking processes can be extended to include conversion Thisinvolves cooling the cooked grain adding malt slurry and blending before passageto a conversion tube A residence time of 10 min is sufficient for amylolysis to reachequilibrium The mass is then cooled and transferred to the fermentation vessel Themost widely used enzymes are heat stable α-amylase and amyloglycosidase Themost efficient use is addition of α-amylase at 80C followed by amyloglycosidaseat 55ndash60C (25) The cooking stage requires careful control of temperature andpressure The efficiency of conversion depends on concentration of grist pH andwater composition
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ORDER REPRINTS
34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
by [
Sule
yman
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irel
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vers
itesi
] at
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
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ber
2011
ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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irel
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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yman
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irel
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
Dow
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ded
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irel
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itesi
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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ORDER REPRINTS
34 KOURTIS AND ARVANITOYANNIS
Fermentation (CCP2)
Yeasts are selected in terms of their satisfactory performance in the partic-ular type of mash used The main criteria are fast fermentation rate high ethanolyield high ethanol tolerance and ability to ferment carbohydrates at relativelyhigh temperatures Overheating can be a serious problem and temperatures in thefermentation vessels must be carefully controlled An infection-free yeast is alsorequired for this stage (CCP) For this particular stage the CCPs are similar to thosementioned for wine production in Table 4
Distillation (CCP3)
Alcohol of 96 vol- deionized water and flavorful seeds (anise gum etc)wine or fermented grains are fed into the boilers at concentrations prescribed bythe formulation for large-scale ouzo production traditional production of ouzo andbrandy gin and vodka respectively Distillation is carried out within the range 63ndash80C for 10 to 12 h The percent alcohol volume of the final distillate amounts toabout 5 vv At this step a potential chemical hazard is the formation of ethyl car-bamate as mentioned in wine production The CL for ethyl carbamate is differentper product (ie 150 ppb for wine distillates 400 ppb for fruit brandies 60 ppm forrum 70 ppm for sherry) Since inadequate thermal process might result in a possi-ble microbiological hazard on-line inspection of the thermal processing conditionsand microbiological examination of the distillate are indispensable Moreover thedistillate must satisfy the prescribed standards for the incoming alcohol (97) Wereconsiderable deviations to be observed the responsible person would need to orderthe redistillation or the rejection of the batch Chocolate used for brandy produc-tion undergoes both physical control (microscopy naked eye observation) for theinspection of presence of foreign materials and microbiological examination forE coli (less than 103cfug) and B cereus (CCL = 104 cfug) (9899)
Dilution of Distillate with Alcohol Addition
The produced distillate has a high concentration of flavorful compounds and isdiluted by adding alcohol of 96 vol- thus resulting in a minimum concentrationof distilled alcohol of 40 in the final product in agreement with current legislationfor ouzo production (95)
Storage of Spirit Distillate (CCP4)
The diluted distillate is transferred into stainless steel tanks where it is storedfor about 10ndash15 days stirred continuously so that all components are adequatelydissolved The concentration of cis-anethol should be accurately controlled by
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
by [
Sule
yman
Dem
irel
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vers
itesi
] at
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ber
2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
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ber
2011
ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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yman
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irel
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] at
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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ded
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yman
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irel
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itesi
] at
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ber
2011
ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
Dow
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ded
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yman
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irel
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itesi
] at
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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] at
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ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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yman
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irel
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] at
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ber
2011
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 35
Tabl
e5
Sum
mar
yof
Haz
ards
CC
PsC
Ls
Mon
itori
ngC
orre
ctiv
eA
ctio
nsa
ndPe
rson
nelR
espo
nsib
lefo
rD
istil
led
Spir
itsPr
oduc
tion
Con
trol
-H
azar
dsPr
even
tive
Cri
tical
Lim
itsM
onito
ring
Cor
rect
ive
Res
pons
ible
Proc
ess
Step
(MC
P)a
Mea
sure
sC
CP
Para
met
er(C
Ls)
Proc
edur
esA
ctio
nsPe
rson
nel
Inco
min
gra
wm
ater
ials
(CC
P1)
MC
ontr
olof
stor
age
cond
ition
sC
ertifi
edsu
pplie
rs
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
1031
041
03cf
ug
resp
ectiv
ely
Vis
ualc
ontr
olfo
rm
old
pres
ence
and
mic
robi
o-lo
gica
lcon
trol
Rej
ectio
nof
batc
hC
hang
est
orag
eco
nditi
ons
Qua
lity
cont
rol
man
ager
CC
ertifi
edsu
pplie
rsTo
xic
met
als
pres
ence
(Gre
ekFo
odco
dex)
Aslt
1Pd
lt10
C
dlt
1H
glt
1(m
gK
g)
Toxi
colo
gica
lco
ntro
lwith
AA
S
Cha
nge
supp
lier
Met
hano
lcon
tent
inw
ine
alco
hol
ferm
ente
dgr
ains
lt0
5g
LC
hem
ical
anal
ysis
Cha
nge
supp
lier
Dilu
tion
with
larg
equ
antit
ies
Dis
tilla
tion
(CC
P3)
MG
MP
cont
rolo
fdi
still
atio
npr
oced
ure
freq
uent
clea
ning
Ec
oli
Bc
ereu
sC
lpe
rfri
gens
101
041
03cf
ug
resp
ectiv
ely
Mic
robi
olog
ical
cont
rol
Rej
ectio
nre
dist
illat
ion
ofsp
ecifi
cba
tch
Prod
uctio
nm
anag
er
Tem
pera
ture
and
dist
illat
ion
time
63ndash8
0 Cfo
r10
ndash12
hT
ime-
tem
pera
ture
on-l
ine
mon
itori
ngC
Ure
ade
term
inat
ion
Use
prop
erye
ast
cultu
res
Eth
ylca
rbam
ate
form
atio
n15
0pp
bw
ine
dist
illat
e40
0pp
bfr
uit
bran
dies
60pp
m
rum
70pp
m
sher
rylt
1
Gas ch
rom
atog
raph
yR
ejec
tion
ofsp
ecifi
cba
tch
dilu
tion
with
larg
equ
antit
ies
Stor
age
ofdi
still
ate
(CC
P4)
CC
onte
ntof
tota
lan
etho
lin
cis-
anet
ol
HPL
Can
alys
isR
ecal
lof
spec
ific
dist
illat
eba
tch
Qua
lity
cont
rol
man
ager
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ded
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yman
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irel
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] at
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ber
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
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ber
2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
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ecem
ber
2011
ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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yman
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irel
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itesi
] at
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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ded
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yman
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irel
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itesi
] at
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2011
ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
Dow
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ded
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yman
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irel
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itesi
] at
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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] at
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ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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irel
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] at
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ber
2011
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ORDER REPRINTS
36 KOURTIS AND ARVANITOYANNISA
dditi
onof
deio
nize
dw
ater
(CC
P5)
CFr
eque
ntco
ntro
lon
the
syst
emin
use
GM
P
1W
ater
qual
ityW
ithin
spec
ifica
tions
pres
crib
edin
Dir
ectiv
e80
778
EC
Che
mic
alan
dto
xico
logi
cal
anal
ysis
with
AA
S
1Pa
use
ofw
ater
flow
and
anal
ysis
ofon
eor
mor
esa
mpl
es
Qua
lity
cont
rol
man
ager
Use
ofde
ioni
zer
2E
lect
rica
lco
nduc
tivity
lt20
ms
cmC
ontin
uous
reco
rdin
gof
deio
nize
r
2A
utom
atic
disc
ontin
uatio
nof
the
deio
nize
rB
ottli
ng(C
CP7
)P
Supp
lier
cert
ifica
teB
ottle
spr
oper
for
food
san
ddr
inks
bo
ttles
cond
ition
Abs
ence
ofun
desi
rabl
efo
reig
nm
ater
ials
amppa
rtic
les
rift
sin
the
lute
cra
cks
orsc
ratc
hes
On-
line
visu
alco
ntro
lem
pty
and
full
bottl
e
Rej
ectio
nof
faul
tybo
ttles
Tra
ined
pers
onne
l
Bot
tlepa
ckag
ing
(CC
P8)
PG
MP
Test
ing
ofth
em
achi
nery
App
eara
nce
ofbo
ttles
Abs
ence
ofde
fect
samp
corr
ect
labe
ling
On-
line
visu
alco
ntro
lR
ejec
tion
offa
ulty
bottl
esan
dst
anda
rdiz
atio
nof
the
equi
pmen
t
Tra
ined
pers
onne
l
CD
eter
gent
rem
ains
Com
plet
eab
senc
eC
hem
ical
anal
ysis
Insp
ectio
nof
CIP
syst
emQ
ualit
yco
ntro
lm
anag
erSt
orag
e(C
CP9
)C
Prop
erst
orag
eco
nditi
ons
Alte
ratio
nof
orga
nole
ptic
prop
ertie
s
Setb
yea
chpl
ant
Org
anol
eptic
anal
ysis
Rej
ectio
nof
faul
tyba
tch
Mod
erat
est
orag
eco
nditi
ons
Tra
ined
pers
onne
l
aM
CP
stan
dsfo
rm
icro
biol
ogic
alc
hem
ical
and
phys
ical
haza
rds
resp
ectiv
ely
Dow
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ded
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yman
Dem
irel
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vers
itesi
] at
09
56 2
6 D
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ber
2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
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ber
2011
ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
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ecem
ber
2011
ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
nloa
ded
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Sule
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irel
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
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ded
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yman
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irel
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itesi
] at
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2011
ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
Dow
nloa
ded
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irel
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itesi
] at
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
Dow
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] at
09
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2011
ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
Dow
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] at
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ecem
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2011
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irel
Uni
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itesi
] at
09
56 2
6 D
ecem
ber
2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 37
HPLC The CCL for cis-anethol is 1 of total anethol In case of deviation thespecific batch distillate should be recalled
Addition of Deionized Water (CCP5)
The stirred product is transferred into tanks where the final product is pre-pared Deionized water aromatic substances (anethol or juniper) and sucrose areadded in ratios according to formulation and the mixture is continuously stirredThe deionized water must comply with the standards as defined by Directive 80778where the CCL for electrical conductivity is 20 mscm and water conductivity valuesare monitored on-line
Maturation (CCP6)
Unlike the other spirits mentioned several brandies are aged for certain periodin wood barrels Aging involves several processes complex phenolic substancesas tannins are extracted from wood structural molecules are depolymerised andextracted to the distillate and reactions may occur between components of woodand distillate (100) These chemical reactions are very important for the organolep-tic quality of the final products which depends on composition of wood differenttreatments in the manufacture of oak barrels and history of the oak barrel (76101)Especially for brandy the presence of scopoletin (determined with HPLC) is con-sidered as a proof of maturation in oak barrels (101) The CL for this step is thesame as mentioned for wine in Table 4
Bottling (CCP7)
The end product is filtered and then pumped into filler machines The bot-tles to be used must be supplied by certified suppliers and undergo a washing step(sterilization) and on-line visual control for the detection of undesirable foreignmaterials particles rifts in the lute cracks or scratches If any physical defectsare detected the bottles are rejected (CCP) Once the bottles are filled they aretransferred to the sealing machine which functions by exerting air pressure ontothe heading of the bottle The sealed bottles move to the standardization machinewhere a code number is printed containing information about production time andthe serial number of the tank where the final product was prepared The code num-ber is very important and useful for traceability reasons such as possible recall ofa certain batch of bottles external audits and company internal control
Labeling
Bottle labeling is carried out with a machine that heats and spreads the adhesiveupon each label Another automatic machine presses labels on the surface of bottles
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011
ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
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ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
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44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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Order now
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ORDER REPRINTS
38 KOURTIS AND ARVANITOYANNIS
The label of the beverage should be in accordance with the principles of the CodexStan 1ndash1985 (Rev 1ndash1991) of the Codex Alimentarius (102)
Bottle Packaging (CCP8)
Bottles are packaged into paperboard boxes of various sizes according to thedimensions of the bottles The encountered hazards can be of physical chemicaland microbiological origin (CCP) Visual control before packaging can assure thatno defective bottles leave the plant Chemical and microbiological control must becarried out to assure the efficiency of cleaning in place system (CIP) and to checkthe possibility of cross-contamination due to the remains of washing solutions
Storage Distribution (CCP9)
During their storage and distribution the bottles of ouzobrandy should bekept away from sunlight that might affect their organoleptic properties (103) Theoccurring hazards CCPs CLs control (preventive) and corrective measures andresponsible personnel are summarized in Table 5
CONCLUSIONS
The implementation of HACCP system to the drinks industry has been of atremendous help in terms of providing the required assurance for worldwide tradeexpansion Although the alcoholic beverages are comparatively safer than otherfoods and drinks because of their high alcohol content identification of potentialhazards and resumption of preventive and corrective actions (whenever required)is of primary importance Establishment of critical control limits in conjunctionwith appropriate and effective monitoring procedures carried out by responsiblepersonnel have managed to minimize the outbreaks of incidents that are hazardousand pernicious for human health
REFERENCES
1 Arvanitoyannis IS Mauropoulos AA Implementation of HACCP System toKaseriKefalotiri and Anevato Cheese Production Lines Food Control 2000 1131ndash40
2 Mossel DAA Corry JEL Struijk CB Baird RM Essentials of the Microbi-ology of Foods Wiley amp Sons Chichester 1995
3 USDA Guidebook for the Preparation of HACCP Plans United States Departmentof Agriculture Food Safety amp Inspection Service Washington DC 1997
4 Mortimore S Wallace C HACCP a Practical Approach 2nd Ed Aspen PublishersInc Gaithersburg MD 1998
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ded
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] at
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ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011
ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
nloa
ded
by [
Sule
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Dem
irel
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vers
itesi
] at
09
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ecem
ber
2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
nloa
ded
by [
Sule
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Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011
ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
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] at
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
Dow
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ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
Dow
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ded
by [
Sule
yman
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irel
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] at
09
56 2
6 D
ecem
ber
2011
Order now
Reprints of this article can also be ordered at
httpwwwdekkercomservletproductDOI101081FRI100000514
Request Permission or Order Reprints Instantly
Interested in copying and sharing this article In most cases US Copyright Law requires that you get permission from the articlersquos rightsholder before using copyrighted content
All information and materials found in this article including but not limited to text trademarks patents logos graphics and images (the Materials) are the copyrighted works and other forms of intellectual property of Marcel Dekker Inc or its licensors All rights not expressly granted are reserved
Get permission to lawfully reproduce and distribute the Materials or order reprints quickly and painlessly Simply click on the Request PermissionReprints Here link below and follow the instructions Visit the US Copyright Office for information on Fair Use limitations of US copyright law Please refer to The Association of American Publishersrsquo (AAP) website for guidelines on Fair Use in the Classroom
The Materials are for your personal use only and cannot be reformatted reposted resold or distributed by electronic means or otherwise without permission from Marcel Dekker Inc Marcel Dekker Inc grants you the limited right to display the Materials only on your personal computer or personal wireless device and to copy and download single copies of such Materials provided that any copyright trademark or other notice appearing on such Materials is also retained by displayed copied or downloaded as part of the Materials and is not removed or obscured and provided you do not edit modify alter or enhance the Materials Please refer to our Website User Agreement for more details
Dow
nloa
ded
by [
Sule
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irel
Uni
vers
itesi
] at
09
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ecem
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 39
5 Buchanan Recycling of Packaging Materials Solid Waste Manag 1998 31 13ndash276 Gould WA Current Good Manufacturing PracticesFood Plant Sanitation CTI
Publishers Inc Baltimore MD 19947 NACMCF Hazard Analysis and Critical Control Point System National Advisory
Committee on Microbiological Criteria for Foods USDA Food Safety amp InspectionService Washington DC 1992
8 FAO 19959 Sandrou DK Arvanitoyannis IS Implementation of HACCP to the Cheese-
Making Industry A Review Food Rev Int 2000 16 (3) 327ndash6810 ISODIS 15161 Guidance on the Application of ISO 9001 and ISO 9002 in the Food
and Drink Industry Geneva 199811 ASNZS 390513 Quality System Guidelines Part 13 Guide to ASAZS ISO
90011994 for the Food Processing Industry Sidney 199812 Anon Beer In New Caxton Encyclopedia The Caxton Publishing Company Ltd
London 1996 Vol 213 Thompson CC Alcoholic beverages and vinegars In Quality Control in the Food
Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego 1987Vol 4 1ndash74
14 Boivin P Procedure for Assessing the Pesticides Used on Malting Barley to Guar-antee the Quality of Malt and Beer In Monograph European Brewery Convention1998 Vol 26 14ndash26
15 Carteus J Derdelinck G Delvaux F HACCP in the Belgian Brewing Industry InMonograph European Brewery Convention 1998 Vol 26 71ndash77
16 Flannigan B The Microflora of Barley and Malt In Brewing Microbiology PriestFG Campbell I Eds Chapman amp Hall London 1996 83ndash126
17 Manke W Rath F Rapid Test for Fusarium as a Practical Tool for HACCP inMalting In Monograph European Brewery Convention 1998 Vol 26 27ndash35
18 Stewart GG Russell I Modern Brewing Technology Compendium Biotechnology1985 3 375ndash381
19 OrsquoRourke Brewing In Industrial Enzymology 2nd Ed Godfrey T West S EdsMacmillan Press Ltd London 1985 104ndash131
20 Young TW The Biochemistry and Physiology of Yeast Growth In Brewing Micro-biology Priest FG Campbell I Eds Chapman amp Hall London 1996 13ndash42
21 Eskin NM Biochemistry of Foods 2nd Ed Academic Press Inc London 199022 Briggs DE Hough JS Stevens R Young TW Malting and Brewing Science
2nd Ed Chapman amp Hall New York 1981 Vol 123 Kennedy AI Hargreaves L Is There Improved Quality in Brewing Through
HACCP In Monograph European Brewery Convention 1998 Vol 26 58ndash7024 Miedaner H Centenary Review Wort Boiling Today Old and New Aspects J Inst
Brew 1986 92 330ndash33525 Varnam AH Sutherland JP Beverages Technology Chemistry and Microbiology
Chapman amp Hall London 199426 Kent NL Evers AD Technology of Cereals An Introduction for Students of
Food Science and Agriculture 4th Ed Elsevier Science Ltd Kidington Oxford1994
27 Atkinson B The Recent Advances in Brewing Technology In Food TechnologyInternational Europe Lavenham Presss Ltd UK 1987 142ndash145
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vers
itesi
] at
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ber
2011
ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
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ded
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
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ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
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nloa
ded
by [
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irel
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vers
itesi
] at
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ecem
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2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
Dow
nloa
ded
by [
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irel
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vers
itesi
] at
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ecem
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2011
ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011
Order now
Reprints of this article can also be ordered at
httpwwwdekkercomservletproductDOI101081FRI100000514
Request Permission or Order Reprints Instantly
Interested in copying and sharing this article In most cases US Copyright Law requires that you get permission from the articlersquos rightsholder before using copyrighted content
All information and materials found in this article including but not limited to text trademarks patents logos graphics and images (the Materials) are the copyrighted works and other forms of intellectual property of Marcel Dekker Inc or its licensors All rights not expressly granted are reserved
Get permission to lawfully reproduce and distribute the Materials or order reprints quickly and painlessly Simply click on the Request PermissionReprints Here link below and follow the instructions Visit the US Copyright Office for information on Fair Use limitations of US copyright law Please refer to The Association of American Publishersrsquo (AAP) website for guidelines on Fair Use in the Classroom
The Materials are for your personal use only and cannot be reformatted reposted resold or distributed by electronic means or otherwise without permission from Marcel Dekker Inc Marcel Dekker Inc grants you the limited right to display the Materials only on your personal computer or personal wireless device and to copy and download single copies of such Materials provided that any copyright trademark or other notice appearing on such Materials is also retained by displayed copied or downloaded as part of the Materials and is not removed or obscured and provided you do not edit modify alter or enhance the Materials Please refer to our Website User Agreement for more details
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011
ORDER REPRINTS
40 KOURTIS AND ARVANITOYANNIS
28 Priest FG Gram-positive Brewery Bacteria In Brewing Microbiology Priest FGCampbell I Eds Chapman amp Hall London 1996 127ndash162
29 Russell I Dowhanick TM Rapid Detection of Microbial Spoilage In BrewingMicrobiology Priest FG Campbell I Eds Chapman amp Hall London 1996209ndash236
30 Storgards E Juvonen R Vanne L Haikara A Detection Methods in Processand Hygiene Control In Monograph European Brewery Convention 1998 Vol 2695ndash107
31 Masschelein H Centenary Review The Biochemistry of Maturation J Inst Brew1986 92 213ndash219
32 Morris TM The Effect of Cold Break on the Fining of Beer J Inst Brew 198692 93ndash99
33 Potter NN Hotchkiss JH Food Science Chapman amp Hall New York 199534 Lillie A Tonnesen A HACCP in Quality Assurance In Monograph European
Brewery Convention 1998 Vol 26 117ndash13035 Jackson G Practical HACCP in Brewing Industry In Monograph European Brew-
ery Convention 1998 Vol 26 50ndash5736 Stadlmayr T Control of the Critical Control Points in the Filling Area In Monograph
European Brewery Convention 1998 Vol 26 108ndash11637 Golz H-J Konic F Lemcke O HACCP and EU Guidelines in the German
Brewing Industry In Monograph European Brewery Convention 1998 Vol 2688ndash94
38 Fricker R The Flash Pasteurization of Beer J Inst Brew 1984 146ndash15239 Van de Berch HJ Developments in Full Bottle Inspection In Monograph European
Brewery Convention 1998 Vol 26 165ndash16840 Codex Food Labelling Complete Texts Joint FAOWHO Food Standards Pro-
gramme Codex Alimentarius Commission FAO Rome 199841 Klaus A Miwa Der Heilige Trank Franz Steiner Verlag Wiesbaden GMBH
Stuttgart 199842 Stewart GG In Alcoholic Beverages in Food and Beverage Mycology Beuchat
LR Ed AVI Book (an imprint of Van Nostrand Reinhold) New York 198743 Harper P The Insiderrsquos Guide to Sake Kodansha International Tokyo 1998 19ndash5844 Hakushika 199645 Codex Pesticide Residues in Food Maximum Residue Limits (MRLs) 2nd Ed Joint
FAOWHO food standards Programme Codex Alimentarius Commission FAORome 1998 Vol 1B
46 Akita 1997 Available at httpwwwmedia-akita (accessedmdash2000)47 Gauntner J The Sake handbook Yenbooks Singapore 1997 11ndash2448 Lotong N Koji In Microbiology of Fermented Foods Wood BJB Ed Elsevier
Applied Science Publishers Ltd Essex 1985 237ndash27049 Kodama K Sake yeast In The Yeasts Rose AH Harrison JS Eds Academic
Press New York 1970 Vol 350 Hayashida S Feng DD Ohta K Composition and Role of Aspergillus Oryzae
Proteolipid as a High Concentration Alcohol Producing Factor Agric Biol Chem1976 40 73ndash78
51 Hayashida S Ohta K Cell Structure of Yeast Grown Anaerobically in Aspergillusoryzae Proteolipid-Supplemented Media Agric Biol Chem 1978 42 1139ndash1145
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011
ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011
ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011
Order now
Reprints of this article can also be ordered at
httpwwwdekkercomservletproductDOI101081FRI100000514
Request Permission or Order Reprints Instantly
Interested in copying and sharing this article In most cases US Copyright Law requires that you get permission from the articlersquos rightsholder before using copyrighted content
All information and materials found in this article including but not limited to text trademarks patents logos graphics and images (the Materials) are the copyrighted works and other forms of intellectual property of Marcel Dekker Inc or its licensors All rights not expressly granted are reserved
Get permission to lawfully reproduce and distribute the Materials or order reprints quickly and painlessly Simply click on the Request PermissionReprints Here link below and follow the instructions Visit the US Copyright Office for information on Fair Use limitations of US copyright law Please refer to The Association of American Publishersrsquo (AAP) website for guidelines on Fair Use in the Classroom
The Materials are for your personal use only and cannot be reformatted reposted resold or distributed by electronic means or otherwise without permission from Marcel Dekker Inc Marcel Dekker Inc grants you the limited right to display the Materials only on your personal computer or personal wireless device and to copy and download single copies of such Materials provided that any copyright trademark or other notice appearing on such Materials is also retained by displayed copied or downloaded as part of the Materials and is not removed or obscured and provided you do not edit modify alter or enhance the Materials Please refer to our Website User Agreement for more details
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 41
52 Lichine A Alexis Lichinersquos Encyclopedia of Wines amp Spirits 6th Ed CassellLondon 1985
53 Ellison P Ash G McDonald C An Expert Management System for the Man-agement of Botrytis Cinerea in Australian Vineyards I Dev Agric Syst 1998 56185ndash207
54 Dibble JE Steinke WE Principles and Techniques of Vine Spraying In GrapePest Management 2nd Ed Flaherty DL Christensen LP Lanini WT MaroisJJ Phillips PA Wilson LT Eds Publ University of California Division ofAgriculture and Natural Resources Oakland CA 1992
55 Maner PJ Stimmann MW Pesticide Safety In Grape Pest Management 2nd EdFlaherty DL Christensen LP Lanini WT Marois JJ Phillips PA WilsonLT Eds Publ University of California Division of Agriculture and Natural Re-sources Oakland CA 1992
56 Oliva J Navarro S Barba A Navarro N Determination of ChlorpyrifosPenconazole Fenarimol Vinclozolin and Metalaxyl in Grapes Must and Wine byOn-line Microextraction and Gas Chromatography J Chromatogr A 1999 83343ndash51
57 Office International de la Vigne et du Vin Pesticide Residue Authorized LimitsClassification by Country Classification by Pesticide O I V Paris 1994
58 Tsakiris AN Oenology From Grape to Wine Psichalos Athens 199659 Zoecklein BW Fugelsang KC Gump BH Nury FS Wine Analysis and Pro-
duction Chapman amp Hall New York 199460 Farkas J Technology and Biochemistry of Wine Gordon amp Breach New York 1984
Vols 1 amp 261 Gnaegi F Aerny J Bolay A Crettenand J Influence des Traitement Viticoles
Antifongiques sur la Vinification et la Qualite du vin Revision Suisse de ViticultureArboriculture et Horticulture 1983 15 243ndash250
62 Constanti M Poblet M Arola L Mas A Guillamon J Analysis of Yeast Pop-ulation During Alcoholic Fermentation in a Newly Established Winery Am J EnolVitic 1997 48 339ndash344
63 Van Vuuren HJJ Jacobs CJ Killer Yeasts in the Wine Industry A review AmJ Enol Vitic 1992 43 119ndash128
64 Sudraud P Chauvet S Activite Antilevure de lrsquoanhydride Sulfureux MoleculaireConnaissance de la Vigne et du Vin 1985 22 251ndash260
65 Pilone GJ Effect of Triadimenol Fungicide on Yeast Fermentation Am J EnolVitic 1986 37 304ndash305
66 Cabras P Meloni M Pirisi FM Farris GAO Fatichenti F Yeast and PesticideInteraction During Aerobic Fermentation Appl Microbiol Biotech 1988 29298ndash301
67 Fatichenti F Farris GA Deiana P Cabras P Meloni M Pirisi FM The Effectof Saccharomyces cerevisiae on Concentration of Dicarboxymide and AcylanilideFungicides and Pyrethroid Insecticides During Fermentation Appl MicrobiolBiotech 1984 20 419ndash421
68 Davis CR Wibowo D Eschenbruch R Lee TH Fleet GH Practical Implica-tions of Malolactic Fermentation A review Am J Enol Vitic 1985 36 290ndash301
69 Guzzo J Jobin M-P Divies C Increase of Sulfite Tolerance in Oenococcus Oeniby Means of Acidic Adaption FEMS Microbiol Lett 1998 160 43ndash47
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011
ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011
ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011
Order now
Reprints of this article can also be ordered at
httpwwwdekkercomservletproductDOI101081FRI100000514
Request Permission or Order Reprints Instantly
Interested in copying and sharing this article In most cases US Copyright Law requires that you get permission from the articlersquos rightsholder before using copyrighted content
All information and materials found in this article including but not limited to text trademarks patents logos graphics and images (the Materials) are the copyrighted works and other forms of intellectual property of Marcel Dekker Inc or its licensors All rights not expressly granted are reserved
Get permission to lawfully reproduce and distribute the Materials or order reprints quickly and painlessly Simply click on the Request PermissionReprints Here link below and follow the instructions Visit the US Copyright Office for information on Fair Use limitations of US copyright law Please refer to The Association of American Publishersrsquo (AAP) website for guidelines on Fair Use in the Classroom
The Materials are for your personal use only and cannot be reformatted reposted resold or distributed by electronic means or otherwise without permission from Marcel Dekker Inc Marcel Dekker Inc grants you the limited right to display the Materials only on your personal computer or personal wireless device and to copy and download single copies of such Materials provided that any copyright trademark or other notice appearing on such Materials is also retained by displayed copied or downloaded as part of the Materials and is not removed or obscured and provided you do not edit modify alter or enhance the Materials Please refer to our Website User Agreement for more details
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011
ORDER REPRINTS
42 KOURTIS AND ARVANITOYANNIS
70 Vaillant H Formysin P Gerbaux V Malolactic Fermentation of Wine Study ofthe Influence of Some Physicochemical Factors by Experimental Design Assays JAppl Bacteriol 1995 79 640ndash650
71 Vivas N Lonvaud-Funel A Glories Y Effect of Phenolic Acids and Athocyaninson Growth Viability and Malolactic Activity of a Lactic Acid Bacterium FoodMicrobiol 1997 14 291ndash300
72 Gnaegi F Sozzi T Les Bacteriophages de Leuconostoc oenos et leur ImportanceOenologique Bulletin drsquo OIV 1983 56 352ndash357
73 Nielsen JC Prahl C Lonvaud-Funel A Malolactic Fermentation in Wine byDirect Inoculation with Freeze-Dried Leuconostoc Oenos Cultures Am J EnolVitic 1996 47 42ndash48
74 Nault I Gerbaux V Larpent JP Vayssier Y Influence of Pre-Culture Conditionson the Ability of Leuconostoc Oenos to Conduct Malolactic Fermentation in WineAm J Enol Vitic 1995 46 357ndash362
75 Martinez RG De la Serrana HLG Mir MV Granados JQ Martinez MCLInfluence of Wood Heat Treatment Temperature and Maceration Time on VanillinSyringaldehyde and Gallic Acid Contents in Oak Wood and Wine Spirit MixturesAm J Enol Vitic 1996 47 441ndash446
76 Mosedale JR Puech JL Wood Maturation of Distilled Beverages Trends inFood Sci Tech 1998 9 95ndash101
77 Viriot C Scalbert A Lapierre C Moutounet M Ellagitanins and Lignins inAging of Spirits in Oak Barrels J Agric Food Chem 1993 41 1872ndash1879
78 Towey JP Waterhouse AL Barrel-to-Barrel Variation of Volatile Oak Extractivesin Barrel-Fermented Chardonnay Am J Enol Vitic 1996 47 17ndash20
79 Popock KF Strauss CR Somers TC Ellagic Acid Deposition in WhiteWines After Bottling A Wood-Derived Instability Australian Grapegrower andWinemaker 1984 244 87
80 Quinn MK Singleton VL Isolation and Identification of Ellagitannins fromWhite Oak Wood and An Estimation of Their Roles in Wine Am J Enol Vitic1985 35 148ndash155
81 Ranken MD Kill RC Baker C Food Industries Manual 24th Ed BlackieAcademic amp Professional London 1997
82 Ribereau-Cayon P Glories Y Maujean A Dubourdieu D Traite drsquo Oenologie2 Chimie du vin Stabilisation et Traitements Dunod Paris 1998
83 Ubeda JF Briones AI Microbiological Quality of Filtered and Non-FilteredWines Food Control 1999 10 41ndash45
84 Gennari M Negre M Gerbi V Rainondo E Minati JL Gandini A Chlozoli-nate Fates During Vinification Process J Agric Food Chem 1992 40 898ndash900
85 Blade WH Boulton R Absorption of Protein by Bentonite in a Model WineSolution Am J Enol Vitic 1988 39 193ndash199
86 Langhans E Schlotter HA Ursachen der Kupfer-Trung Deutse Weinband 198540 530ndash536
87 Cooke GM Berg HW A Re-Examination of Varietal Table Wine ProcessingPractices in California II Clarification Stabilization Aging and Bottling Am JEnol Vitic 1984 35 137ndash142
88 Simpson RF Amon JM Daw AJ Off-flavor in Wine Caused by GuaiacolFood Tech Australia 1986 38 31ndash33
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011
ORDER REPRINTS
HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011
ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
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ded
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2011
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All information and materials found in this article including but not limited to text trademarks patents logos graphics and images (the Materials) are the copyrighted works and other forms of intellectual property of Marcel Dekker Inc or its licensors All rights not expressly granted are reserved
Get permission to lawfully reproduce and distribute the Materials or order reprints quickly and painlessly Simply click on the Request PermissionReprints Here link below and follow the instructions Visit the US Copyright Office for information on Fair Use limitations of US copyright law Please refer to The Association of American Publishersrsquo (AAP) website for guidelines on Fair Use in the Classroom
The Materials are for your personal use only and cannot be reformatted reposted resold or distributed by electronic means or otherwise without permission from Marcel Dekker Inc Marcel Dekker Inc grants you the limited right to display the Materials only on your personal computer or personal wireless device and to copy and download single copies of such Materials provided that any copyright trademark or other notice appearing on such Materials is also retained by displayed copied or downloaded as part of the Materials and is not removed or obscured and provided you do not edit modify alter or enhance the Materials Please refer to our Website User Agreement for more details
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2011
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HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEM 43
89 Simpson RF Cork Taint in Wine A Review of the Causes Australian Grapegrowerand Winemaker 1990 305 286ndash296
90 Neel D Advancements in Processing Portuguese corks Australian Grapegrowerand Winemaker 1993 353 11ndash14
91 Malfeito-Ferreira M Tareco M Loureiro V Fatty Acid Profiling A FeasibleTyping System to Trace Yeast Contamination in Wine Bottling Plants Int J FoodMicrobiol 1997 38 143ndash155
92 Eschnauer E Lead in Wine from Tin-Leaf Capsules Am J Enol Vitic 1986 37158ndash162
93 De la Presa-Owens C Noble AC Effect of Storage at Elevated Temperatures onAroma of Chardonnay Wines Am J Enol Vitic 1997 48 310ndash316
94 Kontominas MG Volatile Constituents of Greek Ouzo J Agric Food Chem 198634 847ndash849
95 Greek Codex of Foods and Drinks Greek Ministry of Economics Athens 199896 Heath HB The Quality Control of Flavoring Materials In Quality control in the
Food Industry 2nd Ed Herschdoerfer SM Ed Academic Press Inc San Diego1985 Vol 4 194ndash287
97 Efstratiadis MM Arvanitoyannis IS Implementation of HACCP to Large ScaleProduction Line of Greek Ouzo and Brandy A Case Study Food Control 2000 1119ndash30
98 Payne WL Duran AP Lanier JM Schwab AH Read RB Jr Wentz BABarnard RJ Microbiological Quality of Cocoa Powder Dry Instant Chocolate MixDry Nondairy Coffee Creamer and Frozen Topping Obtained at Retail Markets JFood Protection 1983 46 733ndash736
99 Mossel DAA Meursing EH Slot H An Investigation on the Numbers andTypes of Aerobic Spores in Cocoa Powder and Whole Milk Nether Milk Dairy J1974 28 149ndash154
100 Bronze MR Boas LFV Belchior AP Analysis of Old Brandy and Oak Extractsby Capillary Electrophoresis J Chromatogr A 1997 768 143ndash152
101 Conner JM Paterson A Piggott JR Changes in Wood Extractives from OakCask Staves through Maturation of Scotch Malt Whisky J Sci Food Agric 199362 169ndash174
102 Codex General Requirements 2nd Ed Joint FAOWHO Food StandardsProgramme Codex Alimentarius Commission FAO Rome 1995 Vol 1B
103 Cigic IK Changes in Odor of Bartlett Pear Brandy Influenced by SunlightIrradiation Chemospere 1999 38 1299ndash1303
104 Directive 925 (1992) Council Directive 925 EEC Official J European Communi-ties Feb 2 1992 No L577
105 Council Directive 9343 EEC on the Hygiene of Foodstuffs June 14 1993106 Official J European Communities July 19 1993 No L175I107 Grassin C Fauquembergue P Wine In Industrial Enzymology 2nd Ed Godfrey
T West S Eds Macmillan Press Ltd London 1996 373ndash383108 Kondo H The Book of Sake Kodasha International Tokyo 1984 61ndash94109 Lea AGH Apple Juice In Production and Packaging of Fruit Juices
and Fruit Beverages Hicks D Ed Van Nostrand New York 1995 182ndash225
Dow
nloa
ded
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irel
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itesi
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09
56 2
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ecem
ber
2011
ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011
Order now
Reprints of this article can also be ordered at
httpwwwdekkercomservletproductDOI101081FRI100000514
Request Permission or Order Reprints Instantly
Interested in copying and sharing this article In most cases US Copyright Law requires that you get permission from the articlersquos rightsholder before using copyrighted content
All information and materials found in this article including but not limited to text trademarks patents logos graphics and images (the Materials) are the copyrighted works and other forms of intellectual property of Marcel Dekker Inc or its licensors All rights not expressly granted are reserved
Get permission to lawfully reproduce and distribute the Materials or order reprints quickly and painlessly Simply click on the Request PermissionReprints Here link below and follow the instructions Visit the US Copyright Office for information on Fair Use limitations of US copyright law Please refer to The Association of American Publishersrsquo (AAP) website for guidelines on Fair Use in the Classroom
The Materials are for your personal use only and cannot be reformatted reposted resold or distributed by electronic means or otherwise without permission from Marcel Dekker Inc Marcel Dekker Inc grants you the limited right to display the Materials only on your personal computer or personal wireless device and to copy and download single copies of such Materials provided that any copyright trademark or other notice appearing on such Materials is also retained by displayed copied or downloaded as part of the Materials and is not removed or obscured and provided you do not edit modify alter or enhance the Materials Please refer to our Website User Agreement for more details
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011
ORDER REPRINTS
44 KOURTIS AND ARVANITOYANNIS
110 National Institute of Agricultural Botany NIAB Farmerrsquos Leaflet No 8Recommended Varieties of Cereals 1998
111 Nunokawa Y Sake In Rice Chemistry amp Technology Houston DF Ed AmericanAssociation of Cereal Chemists Inc St Paul 1972
112 Office International de la Vigne et du Vin Codex Oenologique InternationalComplements OIV Paris 1990
113 Paine FR Aseptic Processing In Modern Processing Packaging and DistributionSystems for Food Paine FA Ed Blackie Academic amp Professional 1995 20ndash35
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011
Order now
Reprints of this article can also be ordered at
httpwwwdekkercomservletproductDOI101081FRI100000514
Request Permission or Order Reprints Instantly
Interested in copying and sharing this article In most cases US Copyright Law requires that you get permission from the articlersquos rightsholder before using copyrighted content
All information and materials found in this article including but not limited to text trademarks patents logos graphics and images (the Materials) are the copyrighted works and other forms of intellectual property of Marcel Dekker Inc or its licensors All rights not expressly granted are reserved
Get permission to lawfully reproduce and distribute the Materials or order reprints quickly and painlessly Simply click on the Request PermissionReprints Here link below and follow the instructions Visit the US Copyright Office for information on Fair Use limitations of US copyright law Please refer to The Association of American Publishersrsquo (AAP) website for guidelines on Fair Use in the Classroom
The Materials are for your personal use only and cannot be reformatted reposted resold or distributed by electronic means or otherwise without permission from Marcel Dekker Inc Marcel Dekker Inc grants you the limited right to display the Materials only on your personal computer or personal wireless device and to copy and download single copies of such Materials provided that any copyright trademark or other notice appearing on such Materials is also retained by displayed copied or downloaded as part of the Materials and is not removed or obscured and provided you do not edit modify alter or enhance the Materials Please refer to our Website User Agreement for more details
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011
Order now
Reprints of this article can also be ordered at
httpwwwdekkercomservletproductDOI101081FRI100000514
Request Permission or Order Reprints Instantly
Interested in copying and sharing this article In most cases US Copyright Law requires that you get permission from the articlersquos rightsholder before using copyrighted content
All information and materials found in this article including but not limited to text trademarks patents logos graphics and images (the Materials) are the copyrighted works and other forms of intellectual property of Marcel Dekker Inc or its licensors All rights not expressly granted are reserved
Get permission to lawfully reproduce and distribute the Materials or order reprints quickly and painlessly Simply click on the Request PermissionReprints Here link below and follow the instructions Visit the US Copyright Office for information on Fair Use limitations of US copyright law Please refer to The Association of American Publishersrsquo (AAP) website for guidelines on Fair Use in the Classroom
The Materials are for your personal use only and cannot be reformatted reposted resold or distributed by electronic means or otherwise without permission from Marcel Dekker Inc Marcel Dekker Inc grants you the limited right to display the Materials only on your personal computer or personal wireless device and to copy and download single copies of such Materials provided that any copyright trademark or other notice appearing on such Materials is also retained by displayed copied or downloaded as part of the Materials and is not removed or obscured and provided you do not edit modify alter or enhance the Materials Please refer to our Website User Agreement for more details
Dow
nloa
ded
by [
Sule
yman
Dem
irel
Uni
vers
itesi
] at
09
56 2
6 D
ecem
ber
2011