An intensive training course entitled

Skills in Controlling Critical Points in the Halal Industry and its Services.

A prerequisite of Halal Lead Auditor

Halal Critical Points of Animal Source Materials

The Third Gulf Conference on Halal Industry and its Services

13-15 May, 2014Sheraton Hotel, State of Kuwait

Professor Mian N. RiazDirector, Food Protein R&D Center, Graduate Faculty, Nutrition and Food

Science Department, The Texas A&M University System

المكثفة الدورة التدريبية مھارات التحكم بالنقاط الحرجة في صناعة الحالل وخدماته

2104مايو 12النقاط الحرجة الحالل في المواد ذات األصل الحيوانيفندق الشيراتون، دولة الكويت

The Third Gulf Conference on Halal Industry and its Services

13-15 May, 2014Sheraton Hotel, State of Kuwait

ميان محمد نديم رياض. د.أمدير أبحاث البروتين، جامعة تكساس أيه أند أم، تامو، الواليات المتحدة

األمريكية

66 66 Billions slaughtered each yearBillions slaughtered each year Meat Meat pproduction roduction ddoubled from oubled from 1980 1980 to to 2007 2007 from from

136136..7 7 to to 285285..7 7 Million Million ttonsons Pork Pork aaccounts ccounts 4343%,%, Poultry Poultry 2727%%, Beef/Veal , Beef/Veal 2626% %

World Meat Consumption World Meat Consumption

and others and others 44% %

We consume onlyWe consume only 6868% of chicken% of chicken 6262% of pig % of pig 5454% of bovine% of bovine

5252% f h% f h

Sources of Animal Derived MSources of Animal Derived Materialsaterials

5252% of sheep or goat% of sheep or goat

Remaining millions of lbs of meat transformed into Remaining millions of lbs of meat transformed into food, feed, cosmetic, pharmaceutical and technical food, feed, cosmetic, pharmaceutical and technical useuse

Animal Derived Animal Derived IIngredientsngredients

Widely used in food productsWidely used in food products

UnavoidableUnavoidable

Difficult to substituteDifficult to substitute

Lack of legislative guidelinesLack of legislative guidelines Lack of legislative guidelinesLack of legislative guidelines

Masked by unMasked by un--decipherable chemical namesdecipherable chemical names

Dilemma of Halal Dilemma of Halal CConsumersonsumers

Lack of awareness about animal ingredients Lack of awareness about animal ingredients

Understanding Understanding ppackaging ackaging llabelsabels

Complexity of food Complexity of food iingredientsngredients

Ambiguous food Ambiguous food iingredientsngredients

Diversity of pDiversity of productsroducts

Emerging Emerging nnew ew ffood productsood products

Halal Consumers, therefore, rely only on Halal Halal Consumers, therefore, rely only on Halal logoslogos

Dilemma Dilemma of Halal of Halal CConsumersonsumers

Most Commonly Most Commonly Used Used Animal PartsAnimal Parts The The Unusual Uses Unusual Uses for Afor Animal Body Partsnimal Body Parts

Most Commonly Most Commonly Used Used Animal PartsAnimal Parts

Protein Hydrolysate

Pancreatic Enzyme

Bacteria

INS Number: 243,261-1, 261-2, 262-1, 262-2, 263, 271, 280, 281, 282, 283, 296, 297, 300, 301, 302, 304, 317, 322, 326, 327, 330, 331-2, 331-1, 331-3, 332, 332-2, 333, 350-1, 350 2 351 1 351 2 352 1 352 2 363 381Hydrolysate

CultureMedia

Varieties of Raw Materials

Bacteria

350-2, 351-1, 351-2, 352-1, 352-2, 363, 381, 415, 420, 421, 422, 432, 433, 434, 435, 436, 442, 469, 471, 472b,472c, 472f, 472g, 474, 475, 476, 478, 480, 481-2, 481-2, 482-1, 482-2, 491, 492, 493, 494, 495, 570, 575, 576, 578, 579, 585, 620, 621, 622, 623, 627, 631, 634, 635, 636, 639, 951, 1100, 1520

Chemicals

Animal Animal Derived Derived IIngredientsngredients

Gelatin / CollagenGelatin / Collagen EnzymesEnzymes

Known Ingredients Less Known Ingredients

Mono Mono and and DiDi--GlyceridesGlycerides LecithinLecithin Glycerol / GlycerinGlycerol / Glycerin LardLard TallowTallow Rennet & Pepsin / WheyRennet & Pepsin / Whey Natural & Artificial Natural & Artificial FlavorsFlavors

Amino Amino Acids (Acids (LL--Cysteine)Cysteine) Vitamins & MineralsVitamins & Minerals Hydrocolloids & GumsHydrocolloids & Gums Hydrolyzed Vegetable ProteinHydrolyzed Vegetable Protein Casing (for sausage)Casing (for sausage) Blood (media for microbes)Blood (media for microbes) CastoreumCastoreum

GelatinGelatin

Gelatin Gelatin –– Thoroughly Thoroughly Natural Natural and and HealthyHealthy

•• Gelatin Gelatin is a pure natural protein obtained from animal raw is a pure natural protein obtained from animal raw materials containing materials containing collagen collagen

P d d b th ti l h d l i fP d d b th ti l h d l i f llll•• Produced by the partial hydrolysis of Produced by the partial hydrolysis of collagencollagen

•• Gelatin Gelatin is a natural and healthy foodstuff with a long is a natural and healthy foodstuff with a long traditiontradition

•• The The pure protein offers a large number of as yet unbeaten pure protein offers a large number of as yet unbeaten advantages and plays a major role in the modern food advantages and plays a major role in the modern food industryindustry

•• Gelatin Gelatin is worldwide the most used hydrocolloid due to its is worldwide the most used hydrocolloid due to its unique unique propertiesproperties

Gelatin is MultitalentedGelatin is Multitalented

Gelling, Thickening and StabilizingGelling, Thickening and Stabilizing

Gelatin is UniqueGelatin is Unique Great melt in mouth feelGreat melt in mouth feel

Gelatin forms a thermo reversible gelGelatin forms a thermo reversible gel

Best compared withBest compared with “Replacers”“Replacers”

Food ApplicationsFood Applications

ConfectioneryConfectionery

DessertsDesserts

Meat PreparationsMeat Preparations

Health DrinksHealth Drinks

Uses of Uses of GGelatinelatin Flavored milkFlavored milk

YogurtYogurt

Sour creamSour cream

Cottage cheeseCottage cheese

Imitation dairy productsImitation dairy products

Ice creamIce cream

CheesecakesCheesecakes

MarshmallowMarshmallow

ConfectioneryConfectionery

ChocolatesChocolates

Jellied beefJellied beef

Corned beefCorned beef

Fruit juicesFruit juices

CerealsCereals

Puddings etcPuddings etc

Sources of GelatinSources of Gelatin

Bovine BoneBovine Bone

Bovine HideBovine Hide

Pork SkinPork Skin Pork SkinPork Skin

OthersOthers–– Pig BonePig Bone

–– Fish scaleFish scale

Halal Gelatin MarketHalal Gelatin Market1010%% of the gelatin of the gelatin produced in the world is produced in the world is deemed Halal deemed Halal

4343%% of of world world production of gelatin use pig production of gelatin use pig skinskin

2929%% use bovine hidesuse bovine hides2929%% use bovine hides use bovine hides

2525%% source material is from bonessource material is from bones

7070%% of Gelatin is made in western worldof Gelatin is made in western world

Halal Halal GelatinGelatin Must:Must:

Derived from halal sourcesDerived from halal sources

–– BOVINE animalsBOVINE animals

Slaughtered according to Slaughtered according to shariahshariah

From a plant that produces halalFrom a plant that produces halal gelatingelatin onlyonly

How to Get Halal Gelatin?How to Get Halal Gelatin?

From a plant that produces halal From a plant that produces halal gelatingelatin onlyonly

Gelatin Production ProcessGelatin Production Process

Halal Control Halal Control PPoints in Gelatin oints in Gelatin PProductionroduction

Degreasing

Fresh bones Dry bone Cattle hide

Acid treatment

HCP1

HCP3

HCP2

Lime treatment

Extraction, Evaporation,

Extrusion, Drying

Milling and blending

Packaging and labeling

HCP4

HCP5

HCP6

HCP7

Halal Control Halal Control PPoints in Gelatin oints in Gelatin PProductionroduction

HCP1HCP1: : All raw material All raw material (cattle hides, bones) should (cattle hides, bones) should be Halalbe Halal

HCP2HCP2: : Proper degreasing Proper degreasing to avoid cross contaminationto avoid cross contaminationto avoid cross contaminationto avoid cross contamination

HCP3HCP3: : Vats of acid Vats of acid treatment should be treatment should be dedicated for Halal onlydedicated for Halal only

HCP4HCP4: : Lime treatment Lime treatment should also have vats should also have vats dedicated specifically for dedicated specifically for HalalHalal

Halal Control Halal Control PPoints in Gelatin oints in Gelatin PProductionroduction

HCPHCP55: : Extraction, Extraction, evaporation, extrusion, and evaporation, extrusion, and drying must be done in drying must be done in clean equipmentclean equipment

CC HCPHCP66: : Milling and Milling and blending equipment should blending equipment should be cleanbe clean

HCPHCP77: : Must be packed in Must be packed in clean containersclean containers

Basic & Halal SCM From Farm to ForkBasic & Halal SCM From Farm to Fork

Halal Perspective

SuppliersVendors

&Consumers

DemandDriven- Halal

Farm/Livestock

Raw : Halal animals Selection Process

Handling -Slaughtering

Ingredient & Additives

BasicPerspective

ManufacturerSuppliers

Driven- Sales

Revenue-Inventory

Cost-On- Time Delivery

Farm/Livestock

Raw : Halal animals

Handling -Slaughtering

Conformity-Safety and

Health-Product

Info.-Quality-Variety-Animal Welfare

-Convenience

etc

Processing & Unit Operations

-Preliminary Operations-Conversion Operations-Preservation Operation

Handling

Packaging

Warehouse/Storage

Logistics/Transportation

Fork - ConsumptionDistribution

Storage/Outlets

-Cycle Time-Lead Time

-Transportation

Cost-Warehouse

Cost-Supplier

Base-Width/Depth

of Distribution

Ensuring Halalness in Gelatin ChainEnsuring Halalness in Gelatin Chain

Only Halal Animals are slaughteredSlaughtering as per Shariah ( in Islamic way)

Bone Mills

Slaughter House

Community SHs & Abattoirs‘ supply Raw bones

1

2

Shipment certificate for each batch

Gelatin Plant

Customer

Traceability- produce only 100% Halal Gelatin

4

5

Ossein Plant Batch Processing3

Apple sauce Apple sauce ProcessingProcessing

Cold PressCold Press±± EnzymeEnzyme

±± AscorbateAscorbate

Receive FruitReceive FruitDumpDumpWash Wash

Inspect Inspect AnalyzeAnalyze

Disintegrate Disintegrate Chop/ MillChop/ Mill

Gelatin to Facilitate Filtration Gelatin to Facilitate Filtration –– Hidden IngredientHidden Ingredient

Cloudy Juice Cloudy Juice Pack Fresh or Pack Fresh or

PasteurizePasteurize

Hot Fill, Hot Fill, Aseptic Aseptic

Process, Process, Concentrate, Concentrate,

or Freezeor Freeze

Enzyme Enzyme TreatmentTreatment

~~1 1 hr. @ hr. @ 5050C C OrOr

~~88Hrs @ Hrs @ 2020CC

Centrifuge or Centrifuge or Coarse FilterCoarse Filter

Haze Proof Haze Proof GelatinGelatin, ,

BentoniteBentonite, or , or HeatHeat

Fine FilterFine Filter

Enzymes in Halal Food Enzymes in Halal Food PProductionroduction

Enzymes play a vital role as catalysts Enzymes play a vital role as catalysts

Bioengineered enzymes are cheaper to produceBioengineered enzymes are cheaper to produce

The use of microbial enzymes is more The use of microbial enzymes is more tibl ith H l l f d d titibl ith H l l f d d ticompatible with Halal food productioncompatible with Halal food production

However, animalHowever, animal--derived enzymes are still used derived enzymes are still used in the food industryin the food industry

Enzymes Enzymes -- Examples of UsesExamples of Uses

Used in food to improve taste, color and Used in food to improve taste, color and texturetexture

Speed up processSpeed up process

Reduce cost of production Reduce cost of production

Increase yield Increase yield

Improve color and aroma Improve color and aroma

Enzymes in Halal Food Enzymes in Halal Food PProductionroduction

In baking, enzymes help to In baking, enzymes help to improve quality, improve quality, freshness, and shelf life of freshness, and shelf life of baked goodsbaked goodsbaked goodsbaked goods

In cheese making, In cheese making, enzymes help to coagulate enzymes help to coagulate milk and aid the ripening milk and aid the ripening processprocess

Enzymes in Halal Food Enzymes in Halal Food PProductionroduction

In juice industry, enzymes increase yields In juice industry, enzymes increase yields and improve color and aromaand improve color and aroma

Enzymes can be used in the extraction of Enzymes can be used in the extraction of vegetable oilvegetable oilvegetable oilvegetable oil

34

HCPs for a Conventional HCPs for a Conventional PProcess forrocess forExtracting Extracting EEnzymes from Animal organsnzymes from Animal organs

Grinding

Releasing

Halal animal organ HCP1

HCP3HCP2

Release agents

Extraction and purification

Standardization

Packaging, labeling HCP5

HCP4

Ingredients

HCPs for a Conventional HCPs for a Conventional PProcessrocessfor Extracting for Extracting EEnzymes from Animal organsnzymes from Animal organs

HCPHCP11: : Animal must be Halal Animal must be Halal for enzyme extractionfor enzyme extraction

HCPHCP22: Use separate : Use separate equipment for Halal and nonequipment for Halal and non--q pq pHalal productsHalal products

HCPHCP33: : Enzymes might not Enzymes might not be present in the tissues in be present in the tissues in soluble form and may need to soluble form and may need to be released or made soluble be released or made soluble to increase the yield by using to increase the yield by using Halal chemicals onlyHalal chemicals only

HCPs for a Conventional HCPs for a Conventional PProcessrocessfor Extracting for Extracting EEnzymes from Animal organsnzymes from Animal organs

HCPHCP44: : Enzyme strength Enzyme strength can be adjusted using several can be adjusted using several ingredients (including ingredients (including preservatives and preservatives and emulsifiers) that should beemulsifiers) that should beemulsifiers) that should be emulsifiers) that should be suitable for Halal productionsuitable for Halal production

HCPHCP55: : Labeling should be Labeling should be properly marked/documentedproperly marked/documented

Advantages of using EnzymesAdvantages of using Enzymes

FastFast

Reaction is specificReaction is specific

Produce little byproductsProduce little byproducts

Cost Cost ssavingaving

To Label or not to Label To Label or not to Label EEnzymesnzymes

Enzymes are usually used as Enzymes are usually used as processing aid processing aid

In cheese and bakery In cheese and bakery products, enzymes might products, enzymes might remain active in the final remain active in the final productproduct

Mention their sources on the Mention their sources on the labellabel

Some time Animal Some time Animal IIngredients are Hiddenngredients are Hidden

Juice Processing with EnzymesJuice Processing with Enzymes

With With Pulp Pulp -- EnzymesEnzymesto improve juice yieldto improve juice yieldto p o e ju ce y e dto p o e ju ce y e d

Without Pulp Without Pulp -- Enzymes Enzymes For For Clarification Clarification

To To Hydrolyze Colloidal PolysaccharidesHydrolyze Colloidal Polysaccharides

Amino AcidsAmino Acids

Natural sources & synthetic Natural sources & synthetic raw material raw material

NaturalNatural –– Extracts from animal Extracts from animal sourcessources

SyntheticSynthetic –– starting materials of starting materials of plant originsplant origins

Amino AcidsAmino Acids

Questionable amino acidsQuestionable amino acids

LL-- cysteinecysteine

LL-- glutamineglutamineLL-- glutamineglutamine

Monosodium glutamate (Ajinomoto?)Monosodium glutamate (Ajinomoto?)

Use of LUse of L--cystinecystine

In Foods:In Foods:

Used in pizza crust, donuts, batters, breading, breading crumbsUsed in pizza crust, donuts, batters, breading, breading crumbs

Natural SourcesNatural Sources::Natural SourcesNatural Sources::

Derivatives of human hair, animal hair and duck feathersDerivatives of human hair, animal hair and duck feathers

Some time Animal Ingredients are HiddenSome time Animal Ingredients are Hidden

Some time Animal Ingredients are HiddenSome time Animal Ingredients are Hidden

Commonly L-Cysteine is made fromfrom human hair and duck feathers

Some time Animal Ingredients are HiddenSome time Animal Ingredients are Hidden

While artificial cysteine is

available, it is cost prohibitive

and mostly used to createand mostly used to create

halal products

How to Cope with Animal Based Ingredients?How to Cope with Animal Based Ingredients?

InIn--depth analysis of the processdepth analysis of the process

Listing animal, plant and synthetic ingredientsListing animal, plant and synthetic ingredients

Scrutiny of ingredients (specification and halal status)Scrutiny of ingredients (specification and halal status)

Substitute ingredients. For example; fish gelatin & Substitute ingredients. For example; fish gelatin & synthetic Lsynthetic L--cysteine) cysteine) yy y )y )

How to Cope with Animal Based Ingredients?How to Cope with Animal Based Ingredients?

Monitoring all major and minor processing aidsMonitoring all major and minor processing aids

Documentation to assure continuous monitoring Documentation to assure continuous monitoring

Periodic monitoring of the sources of ingredients Periodic monitoring of the sources of ingredients

Surprise audits and frequent auditsSurprise audits and frequent audits

P lid ti i l b t t tP lid ti i l b t t t Process validation using laboratory tests Process validation using laboratory tests