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Introduction
Food recalls for chocolate and chocolate products are mainly associated with foodborne pathogen contamination, undeclared allergens and the presence of hazardous extraneous material. Identifying potential hazards and choosing effective control measures is essential to improve the safety of chocolate for human consumption. Additionally, the potential for raw cocoa beans to be contaminated with Salmonella spp. (species) is well established. Canada's Food and Drug Regulations specifically address this hazard with Section B.04.012, which prohibits the sale of cocoa or chocolate products containing Salmonella. Unless the roasting and handling of cocoa beans are adequate and well controlled, the intermediate chocolate products such as cocoa powder, cocoa butter or cocoa liquor may be contaminated with Salmonella spp. (species)Footnote 1.
Control measures for the preparation of chocolate
By proactively identifying potential hazards and control measures during your preparation activities, you enhance the safety of your products, prevent food safety hazards, and reduce the likelihood of contaminated food entering the Canadian market. Hazards may be inherent to chocolate, or they may be introduced during its preparation, movement, or storage. Based on past food recalls, identified below are some examples of potential hazards and control measures to consider when producing chocolate. The measures required are unique to each food business and depend on the size and complexity of your food business and the food you prepare.
Remember, the hazards and control measures in this document are not exhaustive!
When you conduct your hazard analysis, you will need to identify and evaluate all hazards that present a risk of contamination of your food, and determine how you will control these hazards.
Refer to CFIA's Reference Database for Hazard Identification (RDHI) for additional information on potential food safety hazards associated with the preparation and handling of chocolate.
Incoming materials
Potential hazards
- Presence of foodborne pathogens in chocolate blocks and/or other ingredients at risk.
- Presence of undeclared allergens (for example, milk, tree nuts, peanuts) in incoming ingredients and/or packaging materials.
- Presence of hazardous extraneous material in incoming ingredients and/or packaging materials (for example, glass, stones, metal).
Control measure examples
- Obtain a guarantee from the supplier(s) that the chocolate blocks and packaging materials provided meet your purchase specifications (for example the supplier provides a Letter of Guarantee).
- Obtain a certificate of analysis for each lot of ingredients to confirm that they do not contain microbial hazards (for example, Salmonella spp.)
- Inspect all incoming ingredients and materials at receiving to confirm that purchase specifications are met.
- Reject or do not use incoming ingredients and materials that do not meet specifications.
- Analyze representative samples of incoming materials frequently to verify the accuracy of the certificate of analysis and/or that the incoming materials meet the purchase specifications as indicated in the letter(s) of guarantee.
Cutting/ breaking chocolate blocks
Potential hazards
- Contamination of chocolate by metal fragments due to equipment and utensil wear and tear.
Control measure examples
- Monitor equipment and utensils regularly to ensure that they are in good operating condition (for example, not showing signs of wear, no cracks).
Melting tank
Potential hazards
- Presence of undeclared allergens in finished product due to the incorrect addition of rework and/or returned product containing allergens.
- Contamination of chocolate by metal fragments due to equipment and utensil wear and tear.
Control measure examples
- Regularly review the addition of ingredients to ensure that the correct ingredients are added as indicated in the recipe and/or formulation.
- Regularly monitor the addition of rework and/or returned product to ensure that like product is added to like product.
- Regularly monitor equipment and utensils to ensure that they are in good operating condition (for example, not showing signs of wear, no cracks).
Screening/ magnet
Potential hazards
- Contamination of the chocolate with hazardous extraneous material (metallic and/or non-metallic) due to accumulation of hazardous extraneous material and/or damage as a result of inadequate inspection and/or cleaning of the screens.
- Contamination of chocolate with metal fragments due to failure of the magnet to remove metal.
- Contamination of chocolate with hazardous extraneous material (for example, metal accumulated on magnet is released into final product) due to inadequate inspection and/or cleaning of magnet to remove accumulated metal.
Control measure examples
- Regularly monitor equipment (for example, screens and magnets) to ensure that it is in good operating condition (for example, no holes).
- Regularly clean screens and magnets to ensure that they are in good operation condition (for example no accumulation of hazardous extraneous material).
Mixing/ blending
Potential hazards
- Presence of undeclared allergens in finished products due to the incorrect addition of allergens that do not appear on the recipe/formulation.
- Contamination of chocolate by metal fragments due to equipment and utensil wear and tear.
- Utilize dedicated tools and utensils for allergenic ingredients.
Control measure examples
- Regularly monitor the addition of ingredients to ensure that the correct ingredients are added as indicated in the recipe and/or formulation.
- Regularly monitor equipment and utensils (for example, mixers and blenders) to ensure that they are in good operating condition (for example, not showing signs of wear, no cracks) as part of an effective preventive maintenance program.
- Regularly monitor tools and utensils to ensure that they are clean and separated to avoid cross-contamination.
Air cooling
Potential hazards
- Contamination of chocolate with foodborne pathogens due to contact with inappropriately sourced and/or contaminated air used for cooling.
Control measure examples
- Use an appropriate and acceptable source of air and, where necessary, ensure air is filtered.
- Regularly monitor air filters to ensure that they are in good condition and are changed at the recommended frequency.
Storage
Potential hazards
- Growth of foodborne pathogens in chocolate due to inappropriate temperature and humidity control during storage.
- Contamination of ingredients with allergens due to inadequate separation from allergens or products containing allergens in storage.
Control measure examples
- Control temperature/humidity and storage practices to minimize growth of foodborne pathogens.
- Clearly identify allergens and/or products that contain allergens in storage.
- Store allergens and products containing allergens separately from other ingredients and/or products that do not contain allergens.
Packaging/ labelling
Potential hazards
- Contamination with foodborne pathogens due to improper or faulty package seals.
- Presence of undeclared allergens due to incorrect label applied to package and/or incorrect list of ingredients.
Control measure examples
- Monitor packaging to ensure packages are sealed appropriately.
- Implement an effective preventive maintenance program to ensure packaging equipment is functioning as appropriate.
- Monitor labels on product (for example, correct label applied to product, information provided [list of ingredients where applicable] is complete and accurate).
- Review and update labels whenever formulations and/or suppliers change.
For more information see Health Canada's – Allergens and gluten sources labelling – Priority allergens