Quality Control / Assurance

Internal Quality Overview

Qualitative Testing, including iron spot test procedures

Record Keeping and Quality Control Schedule

Quantitative Testing and Composite Samples

Government’s Role In Monitoring

Section 5

Quality Control / Assurance

Quality Control / Assurance

An effective quality assurance and quality control program throughout a country’s flour fortification program:

•Ensures adequate levels of vitamins and minerals to improve nutrition among the population

•Prevents the cost of over-using premix

•Gains customer satisfaction

•Adheres to government regulationsRamadan Deliu, Head of Laboratory at M & Sillosi Milling Company, prepares flour for an iron spot test. Photo by Kate Wheeler.

Quality Control / Assurance

Five parts of the program

InternalFlour millers conduct process control and quality checks

ExternalFood control authorities inspect flour mills and analyze flour samples

Commercial Inspectors check fortified products at retail stores

Intake Household surveys confirm consumption

Impact Biological impact is verified

Source: Chapter eight of the Guidelines on Food Fortification with Micronutrients published by the World Health Organization and the Food and Agricultural Organization of the United Nations

Quality Control / Assurance

Five parts of the program

InternalFlour millers conduct process control and quality checks

ExternalFood control authorities inspect flour mills and analyze flour samples

This tool kit focuses on the internal quality control with the

assumption that the millers purchased high-quality wheat to meet the

customers’ expectations.

The tool kit also highlights the quality assurance process at external

laboratories.

Internal Quality: Overview

Use these five quality control methods in every mill:

1. Monitor the fortification system regularly

2. Conduct qualitative testing regularly

3. Monitor premix feed rate and flour flow rate

4. Keep records of premix usage and fortified flour production

5. Submit samples for quantitative testing

Qualitative Flour Testing Used to:

• Determine if flour sample has been fortified

• Provide visual estimate of fortification level

A common qualitative test is the iron spot test. If iron is detected by this method, it is assumed that other nutrients in the premix are present.

The iron spot test is formally Method 40-40.01: Iron Qualitative Method as approved by the American Association of Cereal Chemists (AACC).Photo by Kate Wheeler.

Iron Spot Test Procedures

1. Take a sample of fortified flour. Make an impression in the sample.

2. Add the reagents with a plastic, disposable dropper.

3. Wait for red spots to appear to indicate presence of iron.

These procedures are for ferrous sulfate, ferrous fumarate and electrolytic iron. See following slides for modified version when using sodium iron EDTA.

Iron Spot Test Procedure

4. Compare test with prepared samples or images such as these to estimate premix addition level

5. Discard sample

22 ppm½ treatment

44 ppmTarget Treatment

88 ppmDouble Treatment

(ppm = parts per million)

Spot Test for Sodium Iron EDTA

When sodium iron EDTA is used, make two changes to the iron spot test procedures:

1. In step one, use a larger sample testing surface to make it easier to observe the smaller quantities of sodium iron EDTA indicated by red spots

2. In step two, omit hydrogen peroxide as a reagent. Hydrogen peroxide is used to change other compounds from ferric to ferrous, but this is not necessary with sodium iron EDTA. Instead, with sodium iron EDTA, hydrogen peroxide prevents the color change

Test Responses• Variability is expected (quantitative test show below)

Target

UpperControlLimit

LowerControlLimit

Iron Spot Test Response

• Make adjustments based on systematic trends over time established by multiple observations.

• Adjusting a premix addition system based on one or two spot test results could widen the system variability and complicate future measurements.

• If 2 out of 5 consecutive samples do not meet expectations, increase the sampling frequency as outlined on the next page.

Iron Spot Test Sample Frequency• If 2 of 5 consecutive samples do not meet the requirements, increase

sampling frequency.

• If the next 2 of 5 samples fail to meet requirements, implement corrective actions. Verify that the feeder is operating properly then consider adjusting the:

- premix feeder control

- flour transport scales

- mixing machinery

• If the next 2 out of 5 consecutive sample fail to meet requirements, stop production until the error is found and corrected.

• Once production restarts, continue frequent sampling.

• Return to normal sampling schedule after 3 consecutive samples are correct.

Iron Spot TestAdvantages

• Simple, fast, inexpensive

• Requires no sample pre-treatment.

• Requires two or three reagents:– potassium thiocyanate (KSCN) or sodium thiocyanate (NaSCN)

– hydrochloric acid (HCI)

– Hydrogen perixode (H202), which is not used with sodium iron EDTA

• Food grade NaSCN is available if desired

• Easy: personnel with minimum training can perform this

Limitation• Not quantitative: does not determine amount of iron in sample.

Qualitative Alternatives to Iron Spot Test, if Desired• Ask premix provider for alternatives • If the premix has riboflavin, use a black light test

– Riboflavin (vitamin B2) will fluoresce under ultraviolet light. Perform this test in a dark room or box using a wet Pekar slick to compare fortified with unfortified flour.

• If the premix has vitamin A, use a color test– Must be done in a laboratory to compare the intensity of color

when vitamin A mixes with copper sulfate.

Record KeepingMaintaining accurate records is an essential part of internal monitoring. Develop a system to track:

• Premix delivery and usage

•Flour production

•Comparison of premix usage with target needs based on flour production

•Results of check weighing tests

•Internal and external quality control testing results.

These records help the mill assure quality and may be required during an external inspection.

Date: Mill:

Flour Production

Time Grade MT Flour % KG % KG % KG

7:00

8:00

9:00

10:00

11:00

12:00

13:00

14:00

Shift Total 0.00 0.00 0 0

Shift TotalMT Flour KG KG KG

0 0.00 0 0

Begin Inventory

Transfer to Mill Floor 0

Total to account for 0 0 0

Closing Inventory

Disappearance 0 0 0

INGREDIENT NEW LOT #EnrichmentMaltBleach

Bleach

Beginning Lot # 700 CCN

Flour Ingredient Usage ReportFirst Shift

SUPERVISOR (name):

701 CCN 052 AGU

OPERATOR (name):

START TIME STOP TIME

Enrichment Malt

Internal Quality Control Schedule

1. Check premix feeder hourly. Make sure the speed detector shows that it is running. Fill hopper if it is low.

2. Run feeder check weights at least every 8 hour shift.

3. Run iron spot tests at least every 8 hour shift.

4. Conduct inventory control of premix usage and fortified flour production at least quarterly.

Detail the quality control responsibility, frequency, protocol, and reporting activities in the mill’s quality assurance manual. Instruct all mill personnel in the procedures. Assign reporting to someone with authority to act on the information.

Internal and External Testing

Central Milling Laboratory

Reference Laboratory

Government Laboratory

Premix Suppliers

Mills

- Quantitative tests of all added nutrients- Checks results and procedures of other labs

- Quantitative tests.- Runs or manages biological testing.- Audits mills.

-Certificate of analysis on premix- Quantitative tests of all added nutrients

-Runs quantitative tests on indicator nutrient and other tests-Audits mills within the company

Laboratory/Production Activities- Fortificant inventory control- Feeder checks- Iron spot tests (if applicable)- Flour sampling

Types of laboratories testing fortified flour

Quantitative Testing• Send samples to laboratory using internationally recognized

methods (AACC or ICC and AOAC)

• Requires sophisticated equipment and careful adherence to protocols due to the small concentration of vitamins and minerals in a flour mixture.

• If results are suspect, the sample can be submitted to a certified, reference laboratory for further analysis.

Laboratories running quantitative tests should:

• Make a sample of standardized flour fortified with a certified level of nutrients as a reference

• Routinely conduct a blind analysis of the reference sample to verify laboratory procedures

Indicator Nutrient Testing• One premix ingredient (usually iron) is typically tested as

“indicator” of others. This is valid for premix that has been properly designed, manufactured and mixed.

• Because the ratio is constant, measuring one nutrients can verify the delivery of the others.

• Assumes no destruction or separation of the indicator nutrient after the premix was added.

Spectrophotometric test for iron

Creating Composite Samples

A composite sample may be used to estimate the weighted average nutrient value in a production run. For a composite sample:

• Take 5 to 10 spot samples representative of a production lot, such as an 8-hour run

• Collect the same sample size

• Distribute sample collection evenly over the production time period

Capability Study GuidelineQuantitative testing determines a mill’s ability to produce a uniformly

fortified flour, meeting specifications.

• Collect individual, not composite, flour samples

• Take 7 or more samples over an 8-hour run

• Calculate the coefficient of variation (CV). The CV is the standard deviation divided by the mean, expressed as a percent

• Identify the analytical error for that lab assay

Example values (developed from FFI references)

Assay Assay CV % Flour Mill Production CV

Iron 13.5 11.3

Folic 10.3 11.7

Thiamine – B1 15.2 10.7

Riboflavin – B2 14.0 11.0

Niacin – B3 14.1 6.2

Control Chart

Target

UpperControlLimit

LowerControlLimit

Government’s Role in Mill Monitoring

Government authorities conduct various roles in flour fortification monitoring, often including:

•Confirming that technical specifications, process control and quality procedures and performance records are maintained at the mill, packaging sites, and points of entry into the country

•Inspecting and verifying legal compliance with the country standard, based on a quantitative assay

– Samples should contain the fortificant, and at least 80% of samples should present the legal minimum.

– Less then 20% of the samples should have a nutrient content above the maximum level, if one has been established.

Plant Audits

• Off-site audit with government official reviewing information supplied by mills

• On-site audit with government official visiting the mill to determine if the mill is properly fortifying flour and to validate data supplied in off-site audits

More Information on Quality Control / Assurance

Chapter eight of the Guidelines on Food Fortification with Micronutrients published by the World Health Organization and the Food and Agricultural Organization of the United Nations

The Flour Fortification Initiative at info@ffinetwork.org