Food Control 79 (2017) 239e253

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Food Control
journal homepage: www.elsevier.com/locate/foodcont

Implementation of traceability and food safety systems (HACCP) under

the ISO 22000:2005 standard in North Africa: The case study of an ice
cream company in Algeria
S. Allata a, A. Valero b, *, L. Benhadja a
a
Laboratory of Vegetal Biotechnologies, Department of Agronomic Sciences, Saad Dahlab University, Blida, Algiers, Algeria
b
Department of Food Science and Technology, University of Cordoba, Campus de Rabanales, Edificio Darwin, 14014, Co
rdoba, Spain

a r t i c l e i n f o a b s t r a c t

Article history: Our study aims at establishing and implementing the HACCP and traceability system, in an integrated
Received 21 December 2016 approach, of ice cream processing in order to control food borne safety hazards, to minimize the pro-
Received in revised form duction and distribution of unsafe or poor quality products, thereby the potential food safety risks and
2 April 2017
associated food recalls. Internal information capture points were identified in ice cream process and the
Accepted 3 April 2017
Available online 4 April 2017
corresponding traceability information to be recorded were determined. Biological, physical, chemical
and allergens hazards that could emerge at each stage of the production were identified. After hazards
identification, the critical control points (CCPs) and operational prerequisites programs (oPRPs) were
Keywords:
Ice cream
selected using a decision tree. Results showed that cleaning-in-place, filtration, pasteurization, cooling
ISO 22000:2005 storage and transport stages were the critical control points identified. Critical limits, monitoring
Operational prerequisite program methods and frequency, responsibilities and corrective actions of the processes are also presented.
HACCP plan Finally, the impact of implementation of food safety system (HACCP) on aerobic plate count (APC) and
Traceability system coliforms in vanilla, strawberry and chocolate flavoured ice cream was investigated. The results of HACCP
adoption showed the reduction of APC in all flavours of the ice cream samples tested, being higher for the
strawberry from 4.18 ± 3.03 till 3.80 ± 2.71 log CFU/g. Besides, a significant decrease of coliforms from
2.39 ± 1.76 till 2.11 ± 1.42 and 2.54 ± 1.62 till 2.02 ± 1.15 log CFU/g was observed in ice cream samples
with a chocolate and strawberry flavour, respectively. In conclusion, the implementation of traceability
and HACCP system, under the ISO 22000 standard has allowed tracking and tracing of ice cream products
improving the microbiological quality of the ice creams.
© 2017 Elsevier Ltd. All rights reserved.

1. Introduction Algeria, the ice cream production raised up to 30 million litres in

Ice cream is a frozen dairy dessert obtained by freezing the ice
cream mix with continuous agitation (Deosarkar, Kalyankar,
Pawshe, & Khedkar, 2016, pp. 385e390). Considered as nutritive
foods (Balthazar et al., 2017), due to its composition, which includes
milk proteins, fat and lactose, as well as other compounds, the ice-
cream might be functional by its supplementation with prebiotic
ingredients or probiotic bacteria (Cruz, Antunes, Sousa, Faria, &
Saad, 2009). Commonly enjoyed by people of all ages (Karaman
et al., 2014), the production and consumption of ice cream
continue to increase year on year (Smith, 2015, pp. 271e284). In
* Corresponding author.
E-mail address: avalero@uco.es (A. Valero).
2015 (Anonymous, 2015).
Dairy products pose a major concern to the dairy industry and
public health authorities (Melo, Andrew, & Faleiro, 2015), as they
can be important sources of foodborne pathogens (Oliver, Jayarao,
& Almeida, 2005). Several authors have reported the outbreaks or
incidents of foodborne illnesses associated with dairy products
(Garcell et al., 2016; Gould, Mungai, & Barton Behravesh, 2014;
Heuvelink et al., 2009; Honish et al., 2005; Johler et al., 2015;
Lindstro€m, Myllykoski, Sivel€
a, & Korkeala, 2010; Motarjemi, Moy,
Jooste, & Anelich, 2014; Papademas & Bintsis, 2010). In industrial-
ized countries, milk and dairy products are involved in 2e6% of
outbreaks of foodborne illnesses (Claeys et al., 2013).
Ice cream, as other dairy product, the possibility of acquiring
food-borne diseases by children, elderly people and immunosup-
pressed patients from this product should not be neglected (Daniels

http://dx.doi.org/10.1016/j.foodcont.2017.04.002
0956-7135/© 2017 Elsevier Ltd. All rights reserved.
240 S. Allata et al. / Food Control 79 (2017) 239e253
et al., 2002; De Farias et al., 2006; El-Sharef, Ghenghesh, Abognah,
Gnan, & Rahouma, 2006; Kanbakan, Con, & Ayar, 2004; M-E-Elahi
et al., 2002; Warke, Kamat, Kamat, & Thomas, 2000).
A study on food-borne disease outbreaks in a number of coun-
tries in Europe and North America (Buvens et al., 2011; CDC, 2015;
Daniels et al., 2002; De Schrijver et al., 2008; Fetsch et al., 2014;
Pouillot et al., 2016) reported outbreaks associated with the con-
sumption of ice cream (El-Sharef et al., 2006).
Classical quality control methods only emphasized on hygienic
quality of final products are inadequate to control hazards occur-
ring at early stages of the process. To provide safe food and prevent
food-borne illness outbreaks, Hazard Analysis Critical Control Point
(HACCP) programs are recommended (Wang et al., 2010).
The HACCP concept is a scientific approach to assess hazards
associated with food production and establish control systems to
ensure food safety (FAO, 1997). It is a preventive system, that takes
the whole chain of food production into consideration before bio-
logical, chemical and/or physical hazards affect the safety of food
products (Food Product Association (FPA), 2006).
Several reports indicated the effects of implementing HACCP on
microbiological quality of food products (El-Hofi, El-Tanboly, &
Ismail, 2010; Kassem, Salem, Ahwal, Saddik, & Gomaa, 2002; Kok-
kinakis, Kokkinaki, Kyriakidis, Markaki, & Fragkiadakis, 2011, 2008;
Nada, Ilija, Igor, Jelena, & Ruzica, 2012; Soriano, Rico, Molto, &
Manes, 2002; Wang et al., 2010).
Moreover, HACCP is recognized in the international food safety
community as a worldwide guideline for controlling food-borne
safety hazards (Kafetzopoulos, Psomas, & Kafetzopoulos, 2013;
Meng et al., 2011). Its principles, detailed in the Codex Alimentar-
ius guidelines, are integrated in International Standard ISO
22000:2005 (ISO 22000, 2005) and have been incorporated in the
Algerian food legislations in 2010, through the Executive Decree No.
10e90 laying down the conditions and procedures for sanitary
accreditation of institutions whose business is related to animals,
animal products and products of animal origin and to their trans-
port (JORA, 2010; Art. 3.).
Nevertheless, the application of HACCP systems does not imply
the existence of a traceability system as a direct consequence of the
documentation procedures. Although one of the HACCP principles
(principle No. 7) states the need to establish documentation and
record-keeping procedures, and although these procedures can
provide useful information for a traceability system, the aims and
scope of documentation in HACCP are different. In the latter, the
aim is to document that the system is under control, and corrective
actions are always taken when pre-defined critical limits are
exceeded (Caporale, Giovannini, Di Francesco, & Calistri, 2001).
A traceability system provides a set of data about the location of
food and food ingredients along the supply chain. They are useful to
identify and track products from origin to consumption while
providing the ability to quickly trace back products at any point in
the food chain (Thompson, Sylvia, & Morrissey, 2005).
There are numerous studies on the implementation of HACCP
system in ice cream factories (Arvanitoyannis, Varzakas, &
Koukaliaroglou-van Houwelingen, 2009; Hung et al., 2015; Lu,
Pua, Liu, Chang, & Cheng, 2014; Papademas & Bintsis, 2002, pp.
213e260), however, traceability systems were not successfully in-
tegrated. In addition, to the best of our knowledge, there is not any
study investigating the implementation of such food safety and
hygiene procedures in the Algerian ice cream industry. The key
issue to add values on food safety is to integrate the traceability
system with HACCP system and use the traceability data to manage
the production process and improve its performance.
The aim of this work was to install the traceability and food
safety systems (HACCP) under the ISO 22000:2005 standard
through conducting a hazard analysis on the ice cream production
line in an Algerian food industry and to identify Critical Control
Points (CCPs) thus setting up an effective preventive system which
will lead to a safer and more efficient production of ice cream.
2. Materials and methods
2.1. Company description
This study was carried out in a food industry, MAZAFROID,
located in north Algeria. The main reason for its selection lies on
being the first ice cream Algerian company which aims at obtaining
the ISO 22000:2005 certification. Besides, implementation and
follow-up of ISO 22000:2005 was agreed with the company di-
rector and food quality staff. Management commitment (ISO
22000, Section 5.) was materialized by communicating to the or-
ganization the importance of meeting this International Standard,
statutory and regulatory requirements as well as customer re-
quirements relating to food safety and by ensuring the availability
of financial, material and human resources (ISO 22000, Section 6.)
for the establishment of the necessary work environment. This
company, founded in 2000 and composed by three production
units with staff of 80 employees, produces cookies, chocolate and
ice creams. The products are directed exclusively to the internal
market. This company has implemented ISO 9001:2008 and ISO
22000:2005 to improve the quality and safety of its products,
customer expectations and product image in the market. Proced-
ures were established in order to identify and monitor CCPs, correct
the process and verify the HACCP plan's effectiveness.
Although the ISO 22000 standard has been completely imple-
mented in all production lines, this work explains only the imple-
mentation of prerequisites programs (PRPs), Hazard Analysis
Critical Control Point (HACCP) principles and traceability system
according to the standard requirements for ice cream processing
line.
2.2. Implementation steps of the HACCP
The tasks outlined in section 7 of ISO 22000: 2005 were fol-
lowed to develop a HACCP plan that includes the following seven
principles:
- Conduct hazard analysis (HA)
- Identify critical control points (CCP)
- Establish critical limits (CL)
- Monitor each CCP
- Establish corrective action
- Establish verification procedures
- Establish record keeping
In this study, prerequisites programs (PRPs) are included in the
HACCP study. Therefore, procedures related to the prerequisite
programs are firstly presented (Wang et al., 2010).
2.3. Principle of traceability
In order to develop a traceability system and to achieve a fully
traceable ice cream chain, a traceability procedure was established
for the elaboration process and information flow at every step in
the chain was collected. Traceability systems require the identifi-
cation of all the physical entities (and locations) from which the
product originates, but also where it is processed, packaged, and
stored. To do so, the HACCP team of the studied food company
carried out a stepwise inspection of the production facilities;
structured interviews with staff; and scrutiny of relevant company
documentation. For an efficient execution of traceability in the
 S. Allata et al. / Food Control 79 (2017) 239e253
company, some principles were followed which many of them were
described in various guidelines as ISO 22005 (2007): i) identifica-
tion of units/batches of all ingredients and products, ii) information
on when and where they are moved and transformed, and iii) a
system linking these data (FSA, 2002).
2.4. Microbiological analyses of ice cream and the impact of the
adoption of HACCP system
Various types and batches of packed ice cream were randomly
collected from ice cream stores for microbial examination: 359
samples (strawberry: n ¼ 105, vanilla: n ¼ 125, chocolate: n ¼ 129)
before HACCP system implementation and 820 samples (straw-
berry: n ¼ 250, vanilla: n ¼ 245, chocolate: n ¼ 325) after HACCP
implementation. The samples are transported in a freezer bag to
the laboratory and stored at 20  C, until testing. All samples were
analyzed within 24 h after collection.
Samples of packed ice cream are analyzed for the aerobic plate
count (APC), coliforms, fecal coliforms, S. aureus and the presence of
Salmonella spp. Samples of packed ice cream are analyzed for the
aerobic plate count (APC), coliforms, fecal coliforms, S. aureus and
the presence of Salmonella spp.
Twenty-five grams of sample are added into 225 ml of sterile
peptone water 0.1% in a conical flask. Serial decimal dilutions are
performed in sterile peptone water. Each of the different dilutions
(1 ml or 0.1 ml) was transferred onto the plates containing appro-
priate cultures media for each analyzed microorganism (Sospedra,
Rubert, Soriano, & Man ~ es, 2013). Aerobic plate count (APC) was
estimated by inoculation into Plate Count Agar (PCA) and incubated
at 30  C for 72 h (ISO 4833, 2003). Total coliforms and fecal co-
liforms were determined by pouring in Violet Red Bile Agar (VRBA)
and incubating at 37  C for 24 h and at 44  C for 24 h (ISO 4832,
2006; NF V08-060, 2009). S. aureus determination is carried out
by spreading on Baird-Parker Agar (BPA) and incubation at 37  C for
24e48 h (ISO 6888-1, 1999). The presence of Salmonella spp. was
detected by following a horizontal method (ISO 6579, 2002).
Twenty-five grams of sample were added to 225 ml of buffered
peptone water and incubated at 37  C for 18 h. Quantities of 0.1 ml
and 1 ml of pre-enrichment culture were inoculated into 10 ml of
Rappaport-Vassiliadis broth and 10 ml of Muller-Kauffmann tetra-
thionate novobiocin broth, and incubated at 42  C and at 37  C,
respectively, for 24 h. Each enrichment broth was used to inoculate
both xylose lysine deoxycholate agar (XLD) and brilliant green
phenol red plates, and incubated then at 37  C for 24 h.
Microbiological results were interpreted in accordance with
microbiological criteria of the official control (Dome
nech, Amoro
s,
Pe
rez-Gonzalvo, & Escriche, 2011) according to the indications of
the Official Journal of the Algerian Republic N 35/1998 (JORA,
1998). The microbiological limits m, level below which all results
are considered satisfactory, of ice cream according to JORA (1998)
are: (a) for aerobic plate count 5.104 CFU/g, (b) for total coliforms
102 CFU/g, (c) for fecal coliforms 1 CFU/g, (d) for S. aureus 10 CFU/g,
(e) for Salmonella spp. absent/25 g.
In this paper, only the enumeration of the aerobic plate count
(APC) and coliforms are presented.
One-way ANOVA (Microsoft Excel 2010) was conducted for re-
sults obtained from enumeration of PCA and coliforms in packaged
ice cream during the examined period expressed as log CFU/g, for
the calculation of mean value, standard error and significance of
difference between mean values. A probability value of less than 5%
was deemed to be significant.
241
3. Results: implementation of PRPs, traceability and food
safety system (HACCP)
The implementation of food safety system (HACCP) is a
continuous process based on the management concepts of an
iterative four-step management methods; the PDCA cycle (plan, do,
check and act).
3.1. Listing the prerequisite programs (PRPs) (ISO 22000, section
7.2.)
PRPs are formally called support programs that provide foun-
dations for HACCP in overall food safety management program (da
Cruz, Cenci, & Maia, 2006). They represent the conditions and the
necessary basic activities to maintain a hygienic environment for
the production, handling and provision of safe finished products all
along the food product process (Gaaloul, Riabi, & Ghorbel, 2011; ISO
22000, 2005). The prerequisite programs in the company are: PRP
personnel hygiene, PRP hygiene of buildings and premises, PRP
cross contamination, PRP disposal of wastes and used water, PRP
water supply, PRP transport and storage, PRP supply management
and products handling, PRP maintenance of equipment, PRP
cleaning and disinfection, PRP pest control. These programs are
verified according to well-defined frequencies.
3.2. Preliminary steps to enable hazard analysis
3.2.1. Food safety team (ISO 22000, section 7.3.2.)
A multidisciplinary team, composed of six people was created in
the company to implement the requirements of the system. The
members of this team were trained thoroughly on the HACCP
system and ISO 22000: 2005 standard. The food safety team
members are: Food safety team leader, Hygienist, Production
manager, Maintenance manager, Supply manager, Sales manager.
3.2.2. Product characteristics and intended use (ISO 22000, section
7.3.3. and 7.3.4.)
The food safety team preceded to a complete description of the
foodstuffs, by identifying their composition, chemical, biological
and physical characteristics, the undergone treatments, durability,
storage conditions and distribution methods. The description
concerns raw materials intermediate and finished products. Table 1
summarizes the characteristics and intended use of ice cream.
3.2.3. Flow diagrams (ISO 22000, section 7.3.5.)
The flow diagram consists in a detailed list of all the stages
needed to prepare ice cream.
The flow diagram should also include the stages after the
product is obtained until it reaches the consumer, in order to
establish circumstances that might potentially affect product safety
and which should be taken into account (Martínez-Rodríguez &
Carrascosa, 2009). The flow diagrams were checked on site by the
food safety team. The stages of the ice cream' production process
are given in Fig. 1.
3.3. Hazard analysis (ISO 22000, section 7.4.)
Identification and assessment of hazards is a key principle for all
HACCP systems (Mortimore, 2001), and a prerequisite to the pro-
tection of public health. To achieve this step, the food safety team
established a procedure specifying the methodology for hazard
analysis.
This procedure specifies the elements of hazard assessment and
identification of CCP and oPRP that apply to the company's various
stages of food production (from the receipt of raw materials to the
242 S. Allata et al. / Food Control 79 (2017) 239e253

Table 1 are selected with the help of the decision tree (Fig. 2). These
Ice cream product description and intended use. measures are classified according to whether they should be
Product Ice cream (flavours: vanilla) is a frozen dairy dessert managed through Operational Prerequisite Programs (oPRPs) or by
combining, in varying proportions, a variety of dairy and
ndez-Segovia
the HACCP plan, using the following criteria (Ferna
non-dairy ingredients, including sweeteners and et al., 2014; ISO 22000, 2005, Section 7.4.4.):
flavouringsa
Composition Water, Powdered skim Milk, sugars, vegetable fat (palm
oil)., whey powder, stabilizers (E410, E412, E407), - Effect of control measure selected on identified hazards (It
emulsifiers (E471), flavours and colorants eliminates or reduces the hazard(s) at acceptable level - It
Origin …. . controls the contamination or proliferation of hazards),
Packaging/size …. .
- Feasibility for monitoring of control measure selected (Contin-
Shelf-life 18 monthsb
Storage and transport 20 to 26  C. uous measurement or in real time - Discontinuous
conditions measurement),
Labelling relating to Product's name, composition, origin, manufacture date, - Place of control measure selected within the system relative to
the expiry date, destination, net weight, storage other control measures (Initial control measure or a previous
food safety temperature
General Pasteurized,
one to other measures established for the same hazard - Final
characteristics Deep frozen control measure),
Physico-chemical aw > 0.95b - Severity of the consequence(s) in the case of failure in control
characteristics pH (6e7)c measure selected functioning (It may involve medical consul-
Acidity (0010e0.015 meq g1)d
tation - It may involve hospitalization).
Viscosity (36.4e68.3 mPas)d
Overrun (27.6e24.7%)d
Microbiological JORA (1998) Critical control point (CCP) is a “step at which control can be
characteristics EU Regulation 2073/2005 amended applied and is essential to prevent or eliminate a food safety hazard
Use of the product Direct consumption or reduce it to an acceptable level” (ISO 22000, Section 3.10.).
The product mentioned is intended for different
segments of population, except sensitive people
A CCP requires:
(Diabetic and person with a milk allergy)
a - Establishing critical limit(s) for criterion(a) separating accept-
Goff (2011).
b
Arvanitoyiannis et al. (2009). ability from unacceptability,
c
Kambamanoli-Dimou (2014). - Validating the critical limit(s),
d
Alamprese, Foschino, Rossi, Pompei, and Savani (2002). - Making the measurements that are needed to monitor criter-
ion(a) and timely detect deviations (Cerf & Donnat, 2011),
- Planning (of) both corrections and corrective actions to be taken
distribution of finished products). It concerns all hazards having a
when critical limits are exceeded (ISO 22000, 2005, Section
direct or indirect impact on the product. 7.6.5.; ISO/FDIS 22004, 2014, Section 5.9.5.).

3.3.1. Hazard identification and determination of acceptable levels
(ISO 22000, section 7.4.2.)
The food safety team established a list of hazards recorded in the
hazard identification card (Table 2), which also specifies their
acceptable levels.
3.3.2. Hazard assessment (ISO 22000, section 7.4.3.)
The identified hazards were evaluated during the scheduled
meetings by the food safety team. Hazard analysis is carried out at
all stages of ice cream production. During hazard analysis, hazards
were categorized into four general areas: biological (pathogens),
chemical (toxic substances), physical (external particles) and al-
lergens hazards. The origins of considered hazards are due to
contamination, multiplication and persistence.
The assessment criteria for each hazard are the severity of known
or potential adverse health effects and its probability of occurrence.
Based on this, information coming from the company's experience
(historical background, customers' and consumers' claims and non-
conformities) is used to set different levels of severity and likeli-
hood by assigning a score to each level. Likelihood and severity are
evaluated according to the criteria and the scores described in
Table 3. A hazard is considered significant if the score resulting
from the multiplication of the probability (P) by the severity (S)
values (P  S) was above 4 (Ferna
ndez-Segovia, Pe
rez-Lla

cer,
Peidro, & Fuentes, 2014). A significant hazard is one of such a na-
ture that their elimination or reduction to an acceptable level is
essential to the production of safe foods (ILSI, 1999).
3.3.3. Selection and assessment of control measures (ISO 22000,
section 7.4.4.)
According to the hazard assessment results, control measures
Operational prerequisite program(s) (oPRP): “PRP identified by
the hazard analysis as essential in order to control the likelihood of
introducing food safety hazards to and/or the contamination or
proliferation of food safety hazards in the product(s) or in the
processing environment” (ISO 22000, Section 3.9.). The elements of
an oPRP are those of a CCP except that no critical limit is required
for the control measure(s) (Cerf & Donnat, 2011), a discontinuous
monitoring is tolerated and at failure to meet action limits or action
criteria, corrective actions and, where appropriate, corrections
should be planned and applied (ISO/FDIS 22004:2014, Section
5.10.3.). The analysis of hazards is shown in Table 4.
3.4. Establishing the operational prerequisite programs (ISO 22000,
section 7.5.) and the HACCP plan (ISO 22000, section 7.6.)
For each critical control point and oPRP, an HACCP plan (ISO
22000, Section 7.6.1.) and oPRP plan (ISO/FDIS 22004, 2014, Section
5.10.1.) are established respectively by specifying the food safety
hazard(s) to be controlled, control measure(s), critical limits (for
the CCP) or action limits or action criteria (for the oPRP), moni-
toring procedure(s) and action(s) to be taken if critical limits or
actions limits or action criteria are exceeded. Tables 5 and 6 illus-
trate an oPRP plan model and the HACCP plan.
3.5. Establishing the verification plan (ISO 22000, section 7.8.)
To check if the HACCP plan is functioning as envisaged, the food
safety team established a verification plan, which specifies the
purpose, the methods, frequencies and responsibilities for the
verification activities. End-product analyses (microbiological ana-
lyses) are made and compared with earlier established reference
 S. Allata et al. / Food Control 79 (2017) 239e253
Fig. 1. The elaboration process of ice cream and the traceability information flow. CCP: Critical Control Point; oPRP: Operational Prerequisite Program.
values. The verification plan model of the operational prerequisite
programs and HACCP plan is represented in Table 7.
3.6. Establishing the documentation and record keeping (ISO
22000, section 4.2.)
In our study, various documentation models were used for
monitoring selected measures control and ensuring appropriate
corrective actions.
Documentation and records are established to provide evidence
of effective implementation of the system (Mortimore, 2001). The
operational documents are divided into two groups: general pro-

cedures and detailed instructions (Dzwolak & Zuraw, 2003). The
procedure model used in this ice cream company is based on the
structure and format based on ISO/TR 10013 (ISO, 2001). Their
structural elements are title, purpose, scope/application, defini-
tions & abbreviations, authorities & responsibilities, description of
activities, records, related documents, references and attachments.
3.7. Microbiological analysis results of ice cream
The results of aerobic plate count (APC) and coliforms analyses
of ice cream samples are presented in Figs. 3 and 4. Taking into
243
account the obtained results, significant decrease (p < 0.05) in the
aerobic plate count of the ice cream samples with a strawberry and
vanilla flavor from 4.18 ± 3.03 till 3.80 ± 2.71 and 4.13 ± 2.90 till
4.01 ± 2.82 log CFU/g, is observed comparing obtained before and
after HACCP implementation, respectively. However, the chocolate
ice cream did not show a significant decrease of APC (p-value:
0.084).
The results of coliforms showed significant decrease (p < 0.05)
in ice cream samples with a strawberry and chocolate flavour from
2.54 ± 1.62 till 2.02 ± 1.15 and 2.39 ± 1.76 till 2.11 ± 1.42 log CFU/g,
prior and after to implementation of HACCP, respectively.
E. coli, Staphylococcus aureus and Salmonella spp. were not
detected in any sample before and after implementation of HACCP
system.
3.8. Traceability system and information flow
Prior to its certification (with ISO 22000:2005), MAZAFROID
factory adopted an ice cream traceability system while being fully
conscious at the outset of the added advantages in achieving
traceability and its compatibility with Hazard Analysis Critical
Control Point (HACCP). A very simple traceability system was put in
place following an effective definition and application of
244 S. Allata et al. / Food Control 79 (2017) 239e253

Table 2
Hazard identification card.

Hazards Severity Sampling Limits References

plana

n c m M

Biological Hazards
Mesophilic aerobic counts at 30  C 1 5 2 5  104 CFU/g 5  105 CFU/g 1
Enterobacteriaceae 1 5 2 10 CFU/g 100 CFU/g 2
Total coliform counts 1 5 2 102 CFU/g 103 CFU/g 1
Fecal coliforms 2 5 2 1 CFU/g 10 CFU/g 1
Salmonella spp. 3 5 0 Absent/25 g 2
Staphylococcus aureus 3 5 2 10 CFU/g 100 CFU/g 1
Listeria monocytogenes 4 5 0 Absent/25 g 2
Staphylococcal enterotoxins 4 Not detected /
Mycotoxins (AFM1) 4 … 3,4
Insects and pests 1 / / Not detected /
Chemical Hazards
Food additives 2 / / / 5,6,7
Residue of detergents 2 / / Not detected /
Residue of migration of substances from packaging materials 2 / / Not detected /
Heavy metals (As, Pb, Cd, Cu) 3 … 3,8
Oil of air compressor 3 Not detected /
Veterinary Drug Residues 2 / / 9
Physical Hazards
Foreign bodies (glass, plastic, wood, metal, etc.) 3 / / 1,5 mm 10
Allergens Hazards
Milk (Milk proteins, lactose). 3 / / / 11

AFM1 ¼ aflatoxin M1, As ¼ Arsenic, Cu ¼ mercury, Cd ¼ Cadmium, Pb ¼ Lead.

(1) JORA N 35 (1998), (2) European Commission (2007), (3) European Commission (2006), (4) Ossa, Hincapie
, & Pen
~ uela, (2015), (5) JORA N 31 (2002), (6) JORA N 30 (2012),
(7) CAC (2004), (8) Directive 98/83/EC (1998), (9) CAC (2015), (10) Arvanitoyannis et al. (2009), (11) European Commission (2003).
a
n ¼ number of units comprising the sample; c ¼ number of sample units giving values between the lower and upper microbiological limits (m and M, respectively).

Table 3 various data during its lifecycle.

Likelihood and severity criteria to assess potential hazards in the elaboration of ice
cream.
Criteria
Likelihood Low Probability: Occurrence may be 3 times per year
Medium Probability: Occurrence may be between 4 and 10
times per year
High Probability: Occurrence may be more than 11 times per
year
Severity Low Severity: The hazard can produce only minor health
problems
Medium Severity: The hazard may produce some health
problems in immune compromised/allergic individuals, or
may involve medical consultation
High Severity: The hazard may produce significant problems,
not only in immune compromised/allergic individuals, but
also in healthy people, which may involve hospitalization or
potential chronic disease
traceability pillars (Regattieri, Gamberi, & Manzini, 2007).
The first step is the identification of characteristics of product
(Steps 2 of HACCP) (Regattieri et al., 2007). A raw material sheet is
established to document import information regarding raw mate-
rials (received), including: the supplier's name, raw material
denomination, weight, lot number assigned by the supplier, arrival
date. The supplier through a delivered note and a conformity cer-
tificate provides this information.
The product routing and the determination of data to trace and
traceability's tools to use are the other fundamental steps taken
into account in designing this traceability system (Regattieri et al.,
2007). The product life is recorded along the chain through both
production and storage activities. Fig. 1, in the right column, shows
the flow chart of the ice cream production process while, in the left
column related information flow of the traceability system is
described (Steps 5 of HACCP).
Traceability for each lot is ensured thanks to the acquisition of
In storage phase, the raw materials do not require to record that
information, since they can be identified by product labels (Lavelli,
Value 2013).
1
These materials are then weighed and mixed in blenders. Mix-
2 ing phase is an information capture point, processing step in which
recording information is essential to maintain identification of
5 products (Peri, Lavelli, & Marjani, 2004; Thakur & Donnelly, 2010).
Here, the traceability system establishes a link between the raw
1
materials lot and the lot of ice cream obtained; thus, the product
2 information about the raw materials is related to the final product.
Traceability information is manually noted on a production process
sheet. This latter document is prepared to record at each produc-
5
tion: the name of the final product to be obtained, its lot number,
the date of the beginning of the production process, the production
date, the raw materials lot, blender code, tank code and the process
parameters, the pasteurization and aging temperatures and the pH
level. The production process sheet follows the ice cream lot
through all production stages, so that a simple reading of this
document provides the complete history of product.
At the end of the freezing phase, the ice cream is put in the
packaging, which is marked with the GTIN (Global Trade Item
Number) barcode and lot number. This lot number would allow the
product to be traced back through company. It is defined by:
- Trade item code: Company encoded its products and this
encoding is made up of letters and Arabic numbers (Hu, Zhang,
Moga, & Neculita, 2013);
- Blender code: the blenders where the mix is mixed;
- Tank code: the tank where the mix is aged;
- Processing date: represent the date of the beginning of the
process.
Structure of ice cream lot number coding is shown in Fig. 5.
The last step of production process is product delivery to the
 S. Allata et al. / Food Control 79 (2017) 239e253
Fig. 2. Decision tree for HACCP implementation adopted from Horchner et al. (2006).
customers. At this step it is mandatory to link the lot number and
amount of the product obtained to the customers' names (Lavelli,
2013). A delivery note detailing the name and lot number of the
final product, customer's name, and date of shipping must be filled.
GPS antennas ensure traceability in the distribution chain. Such
system would make it possible to track the product even when the
process works irregularly such as delays caused by weather
conditions.
The management of the information included in the several
information capture point defined along the ice cream production
process related on: the correct identification of information con-
tent, location and retrieval (Bertolini, Bevilacqua, & Massini, 2006).
Table 8 presents the information to be captured and methods used
to record it in MAZAFROID.
3.9. Testing in ice cream traceability system: ability to track and
trace products
Once the traceability system is developed, it was tested thor-
oughly in the actual process to evaluate if it worked correctly and
met the requirements. This was carried out by the external quali-
fied auditors/experts; while date and modalities were arranged
with the company owner. The test was an exercise of information
retrieval to trace the history of an ice cream lot chosen by the
auditors.
To conduct this test, an identification of product is carried out by
a simple reading of the lot number and the production date of the
final product. Fig. 6 illustrates the connection between the infor-
mation of the raw materials and the final product lot number. The
lot numbers of final products obtained allowed for the identifica-
tion of note delivery and customers to whom the products were
245
sold (Lavelli, 2013). As can be seen in Fig. 6 all information on
product is connected to the lot number. This latter helped to
identify the production process sheet which reported the ice cream
manufacturing process including raw materials used and their lot
number.
The results of the traceability test were that our system per-
formed its functions as expected (ISO 22000, 2005, Section 7.9.).
Fig. 6 illustrates that ice cream could be both tracked and traced
through MAZAFROID company. The traceability test shows that our
system enables taking and management of quality information and
helps in control for quality and safety of product. With the HACCP,
which has effectively supported traceability system development
and implementation, the food safety team could get the accurate
information on each step of the production chain.
4. Discussion
4.1. Selection and assessment of control measures
During the hazard analysis step, the significance of the hazard is
evaluated. The hazards that have little or no significance, or are
unlikely to occur, are controlled by prerequisite program (routine
employee hygiene practices, cleaning procedures, etc.) and they do
not need necessarily that CCPs are implemented by the HACCP
system (McSwane, Rue, & Linton, 2003, pp. 169e196).
For those hazards with high severity, simple controls might not
be enough to prevent the non-conformity of ice cream, a series of
control measures and corrective actions are needed.
The first CCP suggested in this study was the cleaning-in-place
(CIP) to control the persistence of biological hazards. In dairy, like
any other food industry, an effective cleaning and sanitation
246 S. Allata et al. / Food Control 79 (2017) 239e253

Table 4
Hazard analysis of ice cream conducted in the MAZAFROID.

Process steps Hazards Types Causes (5 M's)a Pb Sc P  S Decision tree d

Preventive measures Record

Qe1 Q.2 Q.3 Q.4 Q.5

Reception Physical: foreign bodies Cf Material (raw 5 1 5 Yes Yes No Yes Yes Visual inspection PRP
(wood, hair, etc.) material/
packaging
material)
Chemical: veterinary C Material (raw 1 2 2 No Conformity certificate of raw materials on delivery. PRP
residues, heavy metals material) Periodic analysis of milk for antibiotic residues. Evaluation
of suppliers.
Biological: pathogenic C Material (raw 1 5 5 Yes Yes No Yes Yes Bulletins of analyses of raw materials on delivery. Periodic PRP
microorganisms material/ analysis of raw materials samples. Evaluation of suppliers
(Salmonella spp., E. coli, packaging
etc.) material)
Storage Chemical: residue of C Method 1 1 1 No Storage of detergent and sanitizers in a separate area to PRP
detergent foods
Biological: pathogenic C/Mg Mother nature 1 5 5 Yes Yes No Yes Yes Suitable storage condition. Application of the First In First PRP
microorganisms (environment) Out (FIFO) system
Method
Biological: insects and C Method 1 1 1 No Carry out adequate treatments regarding the fight against PRP
pests pests at regular intervals.
h
Cleaning-in- Chemical: residue of P Method 1 1 1 No Control of pH of final flushing water at each cleaning PRP
place (CIP) detergents
Biological: pathogenic P Method 1 5 5 Yes Yes Yes Monitoring of concentration, temperature and conduction CCP 01
microorganisms time of caustic soda (1.5%NaOH at 65  C for 30mn), acid (1%
HNO3 at 65  C for 10mn) and sanitizing agent (10 ppm of
iodophore for 20mn).
Weighing and Physical: foreign bodies C Man power 5 1 5 Yes Yes No Yes Yes Staff hygiene control. PRP
Mixing (physical work)
Chemical: excessive food C Method/ 1 1 1 No Designation of formula under the requirement of Standards PRP
additives Machine for Specification, Scope, Application, and Limit of Food
Additives. Calibration of measuring equipment
Biological: pathogenic C Man power 1 5 5 Yes Yes No Yes Yes Staff hygiene control. Staff training on personnel hygiene PRP
microorganisms (physical and hand washing. Respect of cleaning and disinfection
work)/Machine programme
Filtration Physical: foreign bodies P Machine (filter) 5 1 5 Yes Yes Yes Filtration with a mesh diameter 1.5 mm of filter CCP 02
Homogenization Biological: pathogenic C Machine 1 5 5 Yes Yes No Yes Yes Effective CIP (sanitation) programme PRP
microorganisms
Pasteurization Biological: pathogenic P Method 1 5 5 Yes Yes Yes Monitoring of time and temperature of pasteurization CCP 03
microorganisms (80 C/25s)
Cooling Biological: pathogenic M Method 1 5 5 Yes Yes Yes Monitoring of temperature and time profile of cooling post- CCP 04
microorganisms pasteurization (4  C within 1.5 h)
Flavour and Physical: foreign bodies C Man power 1 1 1 No Staff hygiene control. PRP
colorant (hair …)
addition Biological: pathogenic C Raw material/ 1 5 5 Yes Yes No Yes No Control of expiry date before use. Staff hygiene control. PRP
microorganisms Man power/ Respect cleaning and disinfection programme
Machine
Aging Biological: pathogenic M Method 1 5 5 Yes Yes No Yes No Monitoring of time and temperature of aging (4  C/24 h) oPRP
microorganisms 01
Freezing with Chemical: air C Machine 1 1 1 No calibration of centrifugal machine and change of de-oiling PRP
air compressor oil filter of air compressor periodically
incorporation Biological: pathogenic C Raw material 2 1 2 No Filtration and sterilization of air incorporated PRP
microorganisms (air)
Packaging/ Chemical: packaging C Material 1 1 1 No Specifications of packaging materials. PRP
labelling materials substances
Biological: pathogenic C Material 1 5 5 Yes Yes No Yes No Implementation of GHP. Staff hygiene control. PRP
microorganisms (packaging Specifications of packaging materials. Storage in controlled
material)/Man area
power
Allergens: milk proteins, C Method 1 2 2 No Mention of allergen on label. Staff training and label PRP
lactose inspection.
Hardening Biological: pathogenic C Machine 1 5 5 Yes Yes No No Regular cleaning and disinfection PRP
microorganisms
Storage of ice Biological: pathogenic M Method 1 5 5 Yes Yes Yes Monitoring of refrigerator temperature (18  C) CCP 05
cream microorganisms (process)
Transport Biological: pathogenic M Method 1 5 5 Yes Yes Yes Monitoring of ice cream transport truck temperature CCP 06
microorganisms (process) (-18  C)
a
5 M's, Material (raw), Machine (technology), Mother Nature (environment), Man power (physical work), Method (process).
b
P, probability.
c
S, severity.
d
The five questions can be found in Fig. 2.
e
Q, Question.
f
C, Contamination.
g
M, Multiplication.
h
P, Persistance.
 S. Allata et al. / Food Control 79 (2017) 239e253 247

Table 5
Example of operational prerequisite programs (oPRP) defined for the aging processing step.

Hazard Control Validation Monitoring procedures (who, what, when, how) Corrections/Personnel Recording
measures responsible

Multiplication of Aging at 4 C/ Lu et al. Operator, monitoring of aging time and temperature, every 4 h, Recycling of ice cream mix/ Plan oPRP
E. coli, 24 h (2014) visualization on display Operator 01
Salmonella spp,
Staphylococcus
aureus,
Listeria
monocytogenes

Table 6
Example of HACCP Plan (CIP process) against persistence of Listeria monocytogenes, Salmonella spp., E. coli, Staphylococcus aureus and chemicals residues (disinfectants, alkaline
and acidic solutions).

Control measure Critical Validation Monitoring procedures (who, what, Corrections and corrective action/ Recording
limits when, how) Personnel responsible

Pre-rinsing with water (5-10mn), circulating hot NaoH Kumari Operator Remake the CIP if exposure time, Plan
cleaning solution (normally 1.5% NaOH at 65  C for [1.5%, and Monitor the exposure time, temperature and/or concentration of HACCP 01
30min), 1st rinsing (5-10mn), circulating acid (1% 65  C, Sarkar temperature and concentration of cleaning agent are different from
HNO3 at 65  C for 10min), 2nd rinsing again (5- 30 min] (2014) cleaning agent and pH of final recommended values/Operator.
10mn), circulating a sanitizing agent of surface HNO3 [1%, Sharma rinsing once a day Remake the final rinsing if the pH of final
(10 ppm of iodophore for 20min) and 3rd rinsing 65  C, and Visual inspection (thermometer, flushing water exceeds the interval [7e8]/
(5-10mn). 10 min] Anand graduated test tubes, pH meter) Operator.
Iodophore (2002) Calibration of measurements instruments/
[10 ppm, Maintenance manager
20min]

Table 7
Example of a verification plan of the operational prerequisite programs and HACCP plans.

Purpose Verification Verification method Frequency Personnel Recording

parameters responsible

oPRP
oPRP 01 Aging Check the proper functioning of Bacteriological Microbiological analyses of mix Once a External Bulletins of external
thermostat of aging tank parameters: ice cream: week laboratory analyses
E. coli, E. coli (ISO 7251)
Salmonella spp, Salmonella spp. (ISO 6579)
Staphylococcus Staphylococcus aureus
aureus. (ISO 6888-1)
Listeria Listeria monocytogenes
monocytogenes, (ISO 11290-2)
CCP
CCP 01 cleaning-in- Check the Efficacy of CIP Physical Physical analyses of final flushing Once a External Bulletins of external
place (CIP) parameters: water: week laboratory analyses
Colour, odour, Colour (ISO 7887)
Turbidity Turbidity (ISO 7027)

Bacteriological Microbiological analyses of final

parameters: flushing water:
Coliform bacteria Coliform bacteria (ISO 9308-2)
E. coli, E. coli. (ISO 9308-2)
Salmonella spp Salmonella spp. (ISO 19250)

program is part of the process to eliminate microorganisms
(Kumari & Sarkar, 2014). CIP systems provide consistent and
reproducible cleaning and allow full traceability of the cleaning
operations (Moerman, Rizoulie res, & Majoor, 2014, pp. 305e383).
The CIP process consists of a series of treatments including
rinsing, cleaning and disinfecting of surfaces (Pettigrew,
Blomenhofer, Hubert, Groß, & Delgado, 2015). Efficacy of CIP re-
gimes greatly depends on exposure time, temperature and con-
centration of cleaning agent (Bremer, Monk, & Butler, 2002; Parkar,
Flint, & Brooks, 2004). However, a number of studies provide the
evidence of existence of biofilms even after CIP and sanitization
treatment in different segments of pasteurization lines (Sharma &
Anand, 2002). Prevalence of biofilm in dairy environment is a
matter of concern as it can be an important reservoir for food
spoilage and can lead to foodborne outbreaks (Kumari & Sarkar,
2014). Biofilm formation in dairy industries and the biofilm form-
ing abilities' of various microorganisms are reported in several
studies (Kumari & Sarkar, 2014; Lee et al., 2017, 2016; Srey, Jahid, &
Ha, 2013). These biofilms, composed of denatured proteins and
minerals such as calcium phosphate, can be difficult to remove
(Bremer, Fillery, & McQuillan, 2006). A typical cleaning sequence
involves pre-rinsing with water, circulating hot cleaning solution
(normally 1.5% NaOH at 65  C for 30min), rinsing, circulating mild
acid (1% HNO3 at 65  C for 10min), rinsing again, and finally
circulating a sanitizing agent of surface, is effective to eliminate
these impurities (Clark, 2009; Kumari & Sarkar, 2014). Exposure
time, temperature and concentration of cleaning agent influence
CIP effectiveness (Bremer et al., 2002; Parkar et al., 2004).
248 S. Allata et al. / Food Control 79 (2017) 239e253

Fig. 3. Aerobic plate count (APC, log CFU/g) determined in the different flavoured packed ice cream before HACCP implementation (n ¼ 359) and after HACCP implementation
(n ¼ 820) in the studied ice cream company. Bars present mean values with error bars showing standard error of the mean.

Fig. 4. Coliforms (log CFU/g) determined in the different flavoured packed ice cream before HACCP implementation (n ¼ 359) and after HACCP implementation (n ¼ 820) in the
studied ice cream company. Bars present mean values with error bars showing standard error of the mean.

products and packaging during storage and handling, and ensuring

Fig. 5. Structure of the ice cream lot number coding.
The residues of the CIP chemicals, which constitute potential
chemical hazards for public health (Kourtis & Arvanitoyannis,
2001), are monitored by pH measurements of final flushing water
at each cleaning.
The other potential chemical hazards associated with ice cream,
such as veterinary drug residues, food additives, residue of migra-
tion of substances from packaging materials, heavy metals, and oil
of air compressor, are controlled by prerequisite programmes
(PRPs), measures included good manufacturing practices (GMP), in
order to reduce the probability of occurrence of these hazards
(Table 4) (Arvanitoyannis et al., 2009).
Allergens identified in the hazard analysis (Table 4) and
considered potential hazards (Murphy, 2010), are addressed under
prerequisite programmes (PRPs). Their management programs
would be separating allergen from non-allergen ingredients,
proper labeling and packaging of products (Gombas, 2006; IDFA,
2002).
Apart from the microbiological and chemical hazards, equally
important, are the physical potential hazards in dairy products
(Papademas & Bintsis, 2010). Physical hazards commonly result
from accidental contamination and poor food handling practices
that can occur at various points in the food chain (MacSwane, Rue,
& Linton, 2000), and are mainly related to packaging, incorrect
labelling and contaminations with foreign objects (Papademas &
Bintsis, 2010). The filtration was defined as CCP 02 to control the
presence of external particles (glass, plastic, wood, metal, etc.).
Filtering with a mesh diameter 1.5 mm is an effective way to
control these physical hazards. Critical control limits are
1.5e2.0 mm for ferrous foreign matter and 2.5 mm for non-ferrous
(Arvanitoyannis et al., 2009). Other preventive measures, including
visual inspection and preventative maintenance to prevent equip-
ment wear (Murphy, 2010), was implemented in order to minimize
the introduction of hazards to the product through raw materials,
as well as during the production process.
The process of pasteurization was identified as a CCP 03, since
improper pasteurization would allow pathogenic bacteria to sur-
vive and potentially cause health problems of the consumers. The
effect of heat treatment on the inactivation of bacteria and toxins
has been described in several publications (Fine & Gervais, 2005;
Trevisani, Mancusi, & Valero, 2014; Valero, Cejudo, & García-
Gimeno, 2014; van Lieverloo, de Roode, Fox, Zwietering, & Wells-
Bennik, 2013). Among the microorganisms of concern with ice
 S. Allata et al. / Food Control 79 (2017) 239e253 249

Table 8
Information to be captured and recording methods used.

Information Steps Date storage

capture
Main information Method Responsibility Record
point

1 Reception of raw materials Description of the raw material lot (denomination, lot Paper Raw material stores Raw material sheet
number, production date, expiry date, weight, quality manager
specifications, arrival date, supplier's name)
2 Weighing and Product name; ingredients (denomination, lot number); Paper Ice cream preparer Production process
mixing processing date; blender code. sheet
3 Pasteurization Time and temperature of pasteurization Paper Ice cream preparer Production process
sheet
4 Cooling Time and temperature of cooling Paper Ice cream preparer Production process
sheet
5 Aging Time and temperature of aging pH of product; tank code. Paper Ice cream preparer Production process
sheet
6 Freezing Temperature of freezing Paper Ice cream preparer Production process
sheet
7 Packaging/labelling Production date; lot number of ice cream Paper Ice cream preparer Production process
sheet
8 Transport Description of ice cream lot (name, lot number, Paper Commercial manager Ice cream delivery note
production date, total amount, customer's name, date and
time)

Fig. 6. Test of information retrieval to trace the history of an ice cream lot. HACCP: Hazard Analysis and Critical Control Points; CCP: Critical Control Point; oPRP: Operational
Prerequisite Program.

cream the aerobic pathogens, which include Listeria mono-
cytogenes, Salmonella spp. and E. coli. A minimum of 80  C for 25 s is
effective in reducing potential biological hazards in ice cream to
acceptable levels (Arvanitoyannis et al., 2009). To avoid the growth
of any thermotolerant bacteria potentially present, it was essential
to immediately cool the product after heat processing (i.e. tem-
perature reduction from 80 to 4  C in 1 h). The time needed to cool
down the pasteurized mix is the CCP 04. The possible cross
contamination of product after pasteurization can be controlled by
applying strict cleaning and disinfection rules (Jelici
c, Bo
zani
c, &
Krcmar, 2009).
With aging process, stage defined as oPRP 01 to control the
growth of biological hazard, the temperature is maintained to 4 C/
24 h. Pathogens can grow in the temperature range of 20e38  C
(Zhong, 2012) and be of high risk for public health. According
Papademas and Bintsis (2002, pp. 213e260) psychrotrophic mi-
croorganisms can proliferate if ice cream mix is kept at 2e4  C for a
prolonged time period. Growth of bacteria can be controlled by
strict time-temperature control. Consequently, time and tempera-
ture must be carefully monitored during the aging process (Lu et al.,
2014).
Frozen storage and distribution are defined as CCP 05 and 06,
respectively, to inhibit the growth of pathogens (such as
L. monocytogenes). Nevertheless, it was reported that the cell count
of L. monocytogenes remained constant during isothermal frozen
storage of ice cream at 23  C for 90 days (Gougouli, Angelidis, &
Koutsoumanis, 2008), while Salmonella enterica subsp. enterica
could survive in ice cream for 4 months at 20  C (Nassib, Zin El-
Din, & El-Sharoud, 2003). Likewise, according Huba
ckova
&
Rysa

nek (2007), S. aureus could also survive in frozen milk. Main-
tenance of frozen chain at temperatures around 25  C is crucial for
the prevention of ice cream physicochemical and microbiological
quality.
4.2. Effect of HACCP implementation on APC and coliforms in ice
cream
Aerobic plate count (APC) and coliforms are the microbiological
hazards in ice cream; different factors can lead to their proliferation
in food. According to the Food Sanitation Standard of Republic of
Algeria (JORA, 1998), APC, coliforms should not exceed 5  105 CFU/
g, 103 CFU/g, respectively.
250 S. Allata et al. / Food Control 79 (2017) 239e253
In this study, low levels of aerobic plate count and coliforms
were detected in the ice cream samples, prior to implementation of
HACCP (Figs. 3 and 4).
The introduction of HACCP system resulted in reduction in the
level of aerobic plate count and coliforms of the ice cream samples,
especially for the strawberry flavour, probably due to control
measures applied in ice cream processes (Figs. 3 and 4).
The reduction of APC is only 0.38, 0.12 and 0.08 log CFU/g in
strawberry, vanilla and chocolate ice cream samples, respectively,
and 0.52 and 0.28 log CFU/g for coliforms in strawberry and choc-
olate flavour samples, respectively, after HACCP system imple-
mentation (Figs. 3 and 4). This low level of diminution of these
microorganisms in the ice cream can be explained by the impact of
adopting an ISO 9001:2008, before the implementation of HACCP,
on compliance with legal and regulatory requirements (ISO 9001,
2008, Section 7.2.) amongst other the time/temperature of
pasteurization of the mix, the temperature of storage and distri-
bution of ice creams and application of Good Hygiene Practice
(GHP). On the other hand, the use of CIP process results in the
limitation of human involvement in the cleaning and probability of
contamination due to potentially inadequate cleaning of the
equipment in use. The GHP allow the global reduction of the
contaminant load, whether they compromise food safety. This
included, among others: training of personnel on food hygiene,
sanitary conditions of surfaces contacting foods, prevention to
cross-contamination and the importance of maintain a cold chain
during food storage and transport; quality control of raw material
at reception; establishment of cleaning procedure and sanitization.
Implication of hygiene measures and food hygiene knowledge of
food handlers on the microbiological quality of food was indicated
in several studies (Capunzo et al., 2005; Lewis, Thompson, Rao,
Kalavati, & Rajanna, 2006; Martinez-Gonzales et al., 2003). Study
of Costa Dias et al. (2012) showed that the implementation of good
manufacturing practices led to significant reduction in the pop-
ulations of aerobic microorganisms and total coliforms in equip-
ment, as well as the populations of total coliforms in the hands of
food handlers. In our case, the GHP application is mainly important
throughout the process, particularly after pasteurization, to mini-
mize Escherichia coli, salmonella spp. and S. aureus contaminations
by the 5 M's (Material, Machine, Mother Nature, Man power and
Method).
In the literature, the application of HACCP system in dairy es-
tablishments has improved the microbial quality of the dairy
product (Cusato et al., 2013; El-Hofi et al., 2010; Kassem et al.,
2002). Kassem et al. (2002) reported a decrease in APC of ice cream
from 6.1 ± 6.0 log CFU/ml till 3.3 ± 3.0 log CFU/ml after HACCP
implementation. A study by Kokkinakis, Fragkiadakis, Ioakeimidi,
Giankoulof, and Kokkinaki (2008) showed that introduction of
HACCP in an ice cream factory resulted in reduction of total co-
liforms and aerobic plate count in ice cream and environment by
20e35%. Their results indicated a mean reduction of aerobic plate
count from 4.58 to 3.62, from 4.61 to 3.49 and from 5.08 to 3.81 log
CFU/g in samples of ice cream vanilla, strawberry and chocolate
flavoured, respectively, and of total coliforms from 2.20 to 1.57,
from 2.29 to 1.65 and from 2.67 to 1.76 in samples of ice cream
vanilla, strawberry and chocolate flavoured, respectively. Am, Efa,
and Sm (2013) reported reduction in aerobic plate count and co-
liforms from 7.87 to 3.37 log CFU/g and 1.68 to <1 log CFU/g in ice
cream samples after HACCP introduction. Nada et al. (2012) re-
ported reduction in total plate count (TPC) of pasteurized milk from
3.32 ± 0.48 till 3.11 ± 0.30 log CFU/ml. after HACCP implementation.
A study conducted by Cusato et al. (2013), showed that food safety
systems implementation in yogurt production line has resulted by
low level reduction of total coliforms count in yogurt (mean value:
from 1.55 to 1.17 log CFU/g till 1.43e1.26 log CFU/g after the HACCP
application).
4.3. Current hurdles found in traceability systems and potential
challenges for other food industries
Results found in our study showed that implementation of
adequate traceability helped to identify the most critical steps in ice
cream production together with an improvement in final product
quality. However, for small and medium sized companies (SME) the
cost associated to put in place traceability systems is seen as a
barrier for supply chain actors. Also for developing countries lack of
investment in the implementation of traceability systems led to
numerous cases of food outbreaks and fraud practices (Dandage,
Badia-Melis, & Ruiz-García, 2017). Additional hurdles are restric-
tive government marketing standardization, inadequate facilities
for food storing or discontinuous structure along the different food
chain actors (Khalid, 2016).
For SME companies, the use of paper-based systems does not
allow automation and lag correct implementation. In our study, the
use of GPS antennas was applied in the distribution chain to track
the product up to delivery to customers. However, other technol-
ogies could be implemented in situ during the manufacturing
process such as DNA-based techniques, barcodes, holograms, or
RFID but their associated cost makes these techniques hardly put in
practice in most of small and medium-sized companies.
Other food industry sectors must face with heterogeneity in
traceability systems, which is in most cases product related. Over-
all, when different products come from multiple producers, trace-
ability is more difficult to harmonize. Other factors affect to specific
products such as perishability and quality variation in fresh fruits
and vegetables, or lack of labelling information for fishery products.
Mixing transformations create challenges for traceability that are
more severe than other types of transformations (Aung & Chang,
2014). From a SME perspective, perceived market/competition
and operational benefits would help to ensure authenticity of final
products and consumer confidence (Abd Rahman, Singhry,
Hanafiah, & Abdul, 2017).
Non-regulatory food safety management systems have been
reported as useful to overcome the problem of heterogeneity in
traceability implementation (Chen, Flint, Perry, Perry, & Lau, 2015).
They should be accompanied by adoption of Good Agricultural and
Management Practices (GAP and GMP) which integrate physical,
chemical and biological hazards (da Cruz et al., 2006). Especially
Food Allergen Management (FAM) which is being taking place at
industrial level and whose the key elements of its adoption are
related to effective planning of production, cleaning of production
lines, separation, and proper food product labeling (Gojkovic,
Marjanovic-Balaban, Vukic, Gruji
c, & Novakovi
c, 2015). Choi and
Rajagopal (2013) suggested that in order to implement successful
measures to control the food allergen, there is a need to involve
various factors, i.e. knowledge, attitude, practices and specific
training received among the relevance persons. According to our
findings, factors which make it difficult to implement FAM included
access to the validated methods of assessment of cleaning effec-
tiveness in removing specific allergens, as well as good practices in
separation of allergenic and non-allergenic materials during
transport and storage, and personnel training in allergen control
(Dzwolak, 2017; Waisarayutt et al., 2014). Other more oriented
approaches are based on simulation recall methods to determine
the pathway through the supply chain from retailer back to the
origin (Forås, Thakur, Solem, & Svarva, 2015). This is reported as a
cost-effective method and can potentially be applied to different
sectors. However, wholesalers should be well prepared to conduct
trace backs and withdrawals.
 S. Allata et al. / Food Control 79 (2017) 239e253
5. Conclusion
The application of a decision tree shows that CIP, filtration,
pasteurization and cooling, aging, frozen storage and distribution
process are the selected hazard control measures, classified as oPRP
or CCP. The relevant hazards for oPRP 01, CCP 01, critical limits,
monitoring methods and frequency, and corrective actions were
presented in Tables 5 and 6
The results of microbiological analysis of packed ice cream
showed that implementation of HACCP can improve the microbial
quality of ice cream. The traceability installed has authorized a
follow-up of the whole of the batches of dairy ice creams
throughout the line production.
MAZAFROID reported that implementation of HACCP and
traceability system has led to greater efficiency in production, and it
explained that these systems had enabled to track the quality of
raw materials and ice cream and to take immediate action(s) when
problems with safety were reported.
To improve this system the company can place some equipment
such as a metal detector for the control of physical hazards as well
as the adoption of electronic traceability systems.
This research is limited to explain only the implementation of
some requirements of ISO 22000:2005 standard on ice cream
process. However, our findings have implications for many other
parts of the dairy industry. Perspective of the approach and found
results could be applied to other food companies, assessing the
advantages and drawbacks of implementing food safety manage-
ment system in the Algerian food processing sector.
Final considerations of this work are that it might be as a
starting point for further research regarding the development of
food safety management systems by application of predictive
microbiology models and risk assessment schemes.
Acknowledgements
The authors are very grateful to the company MAZAFROID for
collaborating in this study, to Professor O. Cerf and Mr. R. Mpiira for
their enlightening recommendations and reading the article and
the HIBRO research group AGR-170 for providing support in data
processing and analysis of samples.
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