HACCP IN CEREALS INDUSTRY

India is the world's second largest producer of Rice, Wheat and other cereals. The huge demand for cereals in the global market is creating an excellent environment for the export of Indian cereal products. In 2008, India had imposed ban on export of rice and wheat etc, to meet domestic needs. Now, seeing the huge demand in the global market and country's surplus production, Country has lifted the ban, but only a limited amount of export of the commodity is allowed. The allowed marginal quantity of exports cereals could not make any significant impact either on domestic prices or the storage conditions.

India is not only the largest producer of cereal as well as largest exporter of cereal products in the world. India's export of cereals stood at Rs. 58279.80 crore during the year 2014-15. Rice (including Basmati and Non Basmati) occupies the major share in India's total cereals export with 64.40% during the same period. Whereas, other cereals including wheat represents a 35.60 % share in total cereals exported from India during this period. The major importing countries of India's cereals during the period were Iran, Saudi Arabia, Indonesia, UAE and Bangladesh

Cereals are broadly marketed under two segments: Ready-to-eat (RTE) cereals and hot cereals. The market for RTE cereals is much bigger as compared to hot cereals. The RTE cereal had the largest share in the cereal market and was valued at 27.8 billion in 2012. However, the hot cereals are growing at more than double the of RTE cereals due to its increasing consumption in the markets.

Hazard Analysis CriticalControl Point (HACCP) was adopted for the evaluation of food safety hazards in the production of cereal-based industries. HACCP is designed for use in all segments of the food industry from growing, harvesting, processing, manufacturing, distributing and merchandising to preparing food for consumption. The production of safe food products requires that the HACCP system be built upon a solid foundation of prerequisite programs.

The essential steps for HACCP plan development in cereals industry are: assembly of an HACCP team; description of the food and its intended use; identification of the consumers of the food; development and verification of a process flow diagram; conduction of a hazard analysis; identification of critical control points; and establishment of critical limits, monitoring requirements, corrective actions for deviations, procedures for verification, and record-keeping procedures.

In an attempt to improve food safety management and operations, the company has designed a HACCP plan and defined five objectives of its implementation below: 

• To understand and address the hygienic insufficiencies existing at the plant level; 

• To review the flow of materials within the production areas; 

• To identify potential hazards to consumer safety; 

• To manage major hazards and determine preventive and corrective actions at each CCP; 

 • To reduce customer complaints and improve satisfaction

In cereals industry improper packaging leads to microbiological contamination which causes serious health risks. Avoiding microbial contamination in every stages employer should have knowledge about HACCP and its application.

Implementing a successful HACCP program requires a team effort. The HACCP team should be a multi-disciplinary group that has a complete understanding of the process and complete control to make the necessary changes required to implement a HACCP plan. In cereals industry HACCP training should be given to members in every units.

HACCP is a management tool which can be applied to a wide range of simple and complex operations and is not restricted to large organizations. The adoption of HACCP is not restricted to food business operations; it can be used to assure food safety at all stages of the food chain including on farm. The benefits of HACCP in cereals industry includes Increase customer and consumer confidence, reduce costs through reduction of product losses and rework, reduce risks of recalls and product withdrawals thus reducing costs associated with insurance and business liability protection, increase focus and ownership of food safety, simplify inspections primarily because of record keeping and documentation, provide consistent quality product.