The application of the hazard analysis and control points (HACCP) in an ice cream production plant.

The HACCP system is applied in the present study as a preventive food safety approach to control some hazards appearing in one of the ice cream production plants in Egypt. The problem comprised the presence of bacteriological and some chemical contamination in most of the company products. Before applying the HACCP system, the samples examination showed high total mesophilic plat count in 50% of the samples and high coliform count in all samples compared to the level recommended in the Egyptian standards. The highest staphylococcal count (negative for coagulase test) obtained was that of chocolate (1.3 x 10(4) CFU/g) followed by mango ice cream (l.0 x 10(4) CFU/g). Faecal coliform was only positive in mango ice cream. Additionally, the levels of lead, iron and copper have been determined. Copper was higher than the recommended level in all samples and ranged between 0.46 ppm in pistachio ice cream and 2.48 ppm in chocolate ice cream. Most of the CCPs in the ice cream production were mainly due to improper handling and practices throughout the processing steps and also related to the lack of food hygiene knowledge of the workers. The application of HACCP system has successfully reduced the bacteriological hazards in all samples. After applying the corrective actions, the highest total aerobic plate count (8.0 x 10(4)) was that of Swiss chocolate ice cream which corresponds to 50% of the recommended level by the Egyptian standards. Coliform count was less than 10 in all samples except mango ice cream (43 MPN). A significant decrease in staphylococcal count, faecal coliform and trace metal contamination was also recorded in all samples.