GMP GUIDE

FOR
HALAWA AND TAHINA
PRODUCTION
2015
 GMP GUIDE
FOR
HALAWA AND TAHINA
PRODUCTION
2015

The Quality Programme (QUALEB) - Phase III

“Further Strengthening of Quality Management
Capabilities & Infrastructure in Lebanon”- EU Funded
(EuropeAid/132048/D/SER/LB Contract Reference: ENPI/2012/297-962)
‫برنامج تقوية إدارة الجودة وقدراتها وبنيتها التحتية في لبنان‬

November 2015
 Produced in the framework
of the Quality Programme - QUALEB Phase III - an EU funded project:

“Further strengthening of quality management,

capabilities and infrastructure in Lebanon”

Hosted at the
Ministry of Economy and Trade EuropeAid / 132048 / D / SER / LB

This report is the property of

QUALEB - the Quality Unit at the Ministry of Economy and Trade,
and should not be copied,
adopted or translated in any form,
without the prior written permission of QUALEB.

Edited by QUALEB,
the Quality Unit at the ministry of Economy and Trade,
Lebanon

Azarieh Building - Block 01 - 8th floor, downtown Beirut

Tel.: +961 1 982357 - Fax: +961 1 982299 - www.qualeb.org
 CONTENTS

Preface 5
.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1- INTRODUCTION .................................................................................................. 7
2- Scope ............................................................................................................................ 9
3- Relevant definitions .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4- Objectives .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5- BUILDING LOCATION AND DESIGN .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.1- Internal factory layout .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2- Building structure ...................................................................................... 16
5.3- Material and personnel flow ............................................................... 17
5.4- Equipment ...................................................................................................... 19
5.5- Containers for waste disposal ............................................................ 19
6- FACILITIES .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.1- Water and steam supply ........................................................................ 21
6.2- Drainage and waste disposal .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.3- Cleaning ........................................................................................................... 23
6.4- Personal Hygiene facilities .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.5- Temperature, air quality and ventilation .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.6- Lighting .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.7- Storage .............................................................................................................. 27
7- PROCESS CONTROL .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.1- PROCESS FLOW CHARTS .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.1.1- FLOW CHART TAHINA TRADITIONAL BATCH PROCESS 30 ..

7.1.2- FLOW CHART TAHINA CONTINIOUS PROCESS .................... 31

7.1.3- FLOW CHART HALAWA TRADITIONAL ...................................... 32

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 7.2- Microbiological, physical and chemical contamination 33 .. .

7.3- Reception and storage of incoming Material .......................... 33

7.4- Storage and Delivery of semi-Finished product .. . . . . . . . . . . . . . . . . . . . 34
7.5- Storage and delivery of finished product .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.6- Quality of the Water as an ingredient .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.7- Production management and hygienic parameters ............ 36
7.8- Quality assurance and quality control ........................................... 38
7.9- Record keeping .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.10- Traceability and Recall ............................................................................. 39
8- MAINTENANCE AND SANITATION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.1- Equipment and tools ................................................................................... 41
8.1.1- Special requirements for some Tahina and Halawa equipment 43 ..

8.1.2- Cleaning procedures (SSOP) and Programs .......................... 45

8.2- Pest Management .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.3- Waste Management. .................................................................................... 48
8.4- Personnel Hygiene ........................................................................................ 48
9- TRANSPORTATION ......................................................................................... 51
10- PRODUCT INFORMATION AND CONSUMER AWARENESS 53 ...

11- TRAINING .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
12- Hazard Analysis for Tahina ................................................................. 57
13- Hazard analysis for Halawa .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
ANNEX 1: Format for a standard operating procedure (SOP) .. . . . . . . . . 67
ANNEX 2: Procedure: Hand washing techniques .................. 69
ANNEX 3: Example of an SSOP .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
ANNEX 4: Example on SOP for Pest Management ............... 75
References ................................................................................................................... 79

4
 PREFACE

The Quality unit at the Ministry of Economy and Trade

implementing the Quality Programme (QUALEB), hosted
at the Ministry of Economy and Trade in Lebanon and
funded by the European Union, started in October 2004
where two phases were successfully implemented to
develop the foundations of national quality infrastructure.
QUALEB phase III has been launched in September 2012
to ensure sustainability and continuity of the programmes’
first two phases results and is being delivered through two
tools: Technical Assistance and Twinning projects, under
the guidance of HE. Dr Alain Hakim, Minister of Economy
and Trade and in collaboration with the Delegation of the
EU to Lebanon.
The objective of both projects is to ensure the safety of
the Lebanese products and increase its competitiveness
on international markets through better compliance to
national and international standards.
This guidelines has been prepared by the experts of
the quality programme in consultation with the Syndicate
of Food Industries (SLFI) in Lebanon, as part of QUALEB
dissemination activities aimed to enhance food safety
knowledge targeting Tahina and Halawa producers.
Sesame seed products Tahina and Halawa are major
food products in the Middle East. The Lebanese Tahina

5
 and Halawa industries are expanding their production
and are exporting products on a worldwide basis. This
sector has been passing through some economic losses
since 2001 due to some rejected products that are
contaminated with Salmonella.
The conventional approach to ensure food quality
and safety, which depends on inspection and testing
of the end products, has proved to be inadequate in
controlling food-borne disease outbreaks. This may be
particularly so in case of traditional foods, because of their
diversity and the great number of personnel involved in
its production.
This guideline discusses the unique characteristics
of Tahina & Halawa, identifies food safety concerns and
addresses an approach based on EU best practices and
Good Manufacturing Practices as well as HACCP System
which is based on training, developing systems for food
hygiene, safety, and monitoring to ensure food safety.
Finally, this guideline provides producers experience
based information that can be translated, integrated and
implemented within the Tahina and Halawa production
processes. We hope that the producers benefit from this
Guide in producing more safe products for consumers
and in preserving their markets and penetrating new
ones.
Ali Berro, PhD
Director, Quality Unit-QUALEB
Ministry of Economy and Trade

6
 1- INTRODUCTION

Tahina and Halawa are two major products consumed

heavily in Lebanon but also exported abroad all over the
world to the Lebanese and Arab diaspora .Those products
are produced mainly from one of the oldest oil crops in
the world, sesame seed. They constitute an important
part of the Lebanese food specialties even though they
are also produced all along the Levant area until Turkey
and Greece. The most solicited source for sesame in
Lebanon is Sudan, in addition to other countries such as
Ethiopia, Nigeria, India and China.
Tahina and Halawa are shelf stable self-preserving
products because of the very low moisture content in their
composition and therefore the final product practically
does not need to undergo any severe treatment for its
preservation. Having said this, seed crops such as sesame
can be exposed during their growth, drying and storage
to a wide range of bacteria from many sources including
soil, manure, irrigation water, wild birds and animals. The
manufacture of Tahina and Halawa must be performed
in hygienic manner in order to assure that they are not
contaminated from external sources.
One of the main safety issues facing Tahina and Halawa
as a consequence is contamination with Salmonella.
Evidence of contamination in Lebanese Tahina obtained

7
 from the Ministry of economy and trade, has shown that
such contamination has been detected in Lebanon and
also has been reported worldwide in countries such as
USA, Sweden, Australia, New Zealand and Canada.
Salmonella contamination has also been detected
in Tahina from other origins, making Salmonella
contamination one of the major challenge of Tahina and
consequently Halawa production.
The reason it is a challenge is the ironic fact that the
very characteristic of Tahina that makes it self-preserving
is also the cause that makes some strains of Salmonella
contamination very difficult to remove. Hence the most
efficient way to obtain a clean Tahina is through the
application of good manufacturing practices and good
sanitation practices that will prevent any serious hazard
to reach or remain in the Tahina and as a result in Halawa.

8
 2- SCOPE

The document is intended to all food processors which

are already producers or are planning to produce Tahina
and Halawa according to HACCP based GMP. It has been
established in order to provide Good manufacturing
practice guidance for the production of Tahina from
raw sesame seed and for the production of Halawa from
Tahina and sugar.
Tahina is the thick liquid product produced from the
peeling, roasting and grinding of sesame seeds; and
Halawa can be defined as the sweet solid mass
produced from the mixing of Tahina with cooked and
aerated sugar
The guide is based on the Codex Alimentarius
principles of food hygiene and addresses all practices and
safety measures starting from the design of the Factory
building until delivery to the market.
The end of the document includes a hazard analysis
table showing potential hazards and their preventive
controls under GMP. It addresses the issue of the heat
treatment of the finished product at the end of the
process adopted by several factories in Lebanon to reduce
the contamination risks. In addition some example SOP s
have been included in the Annexes to provide a guide for
companies on their preparation.

9
 3- RELEVANT DEFINITIONS

Backflow: is defined as the flow of water or other

liquids, mixtures, or substances into a potable water
system from any source, other than the intended source
Cleaning: The removal of soil, food residue, dirt, grease
or other objectionable matter.
Contaminant: any biological or chemical agent, foreign
matter, or other substances not intentionally added to food
which may compromise food safety or suitability.
Cross contamination: The passage of contaminants
from a contaminated source (raw food, surface personnel,
pests…etc.) to another food or any other surface
supposed to be clean.
Disinfection: The reduction, by means of chemical
agents and/or physical methods, of the number of micro-
organisms in the environment, to a level that does not
compromise food safety or suitability.
Flow diagram: A systematic representation of the
sequence of steps or operations used in the production
or manufacture of a particular food item.
Hazard: a biological, chemical or physical agent in, or
condition of, food with the potential to cause an adverse
health effect.

11
 Hazard analysis: The process of collecting and
evaluating information on hazards and conditions
leading to their presence to decide which are significant
for food safety and therefore should be addressed in the
HACCP plan.
Maximum Residue Limit (MRLs): are the upper legal
levels of a concentration for pesticide residues in or on
food or feed based on good agricultural practices and to
ensure the lowest possible consumer exposure.
Preventive measure: means physical, chemical, or
other factors that can be used to control an identified
food safety hazard.
Standard operating procedures (SOPs): are the
detailed written instructions that specify how a test
or administrative procedure is to be performed, or
how a piece of equipment is operated, maintained
and calibrated. SOPs describe the “standard” approved
procedures that are routinely carried out in a GMP facility.

12
 4- OBJECTIVES

Producing Tahina and Halawa in compliance with

international standards of hygiene require that all aspects
of the manufacturing process be addressed and the
relevant parameters be identified.

13
 5- BUILDING LOCATION AND DESIGN

Tahina and Halawa premises shall be designed

constructed and maintained to control the risk of product
contamination
• The building and surrounding area should be such
as can be kept reasonably free of objectionable odors,
smoke, dust, or other contamination;
• The factory should not be located over or under or
very near to animal farms or animal slaughtering areas.
• Factory waste collection and sewage tanks shall
be located away from the factory premises. Factory
should assure that any shared drainage facilities with
other facilities in the area does not affect its environment.
• Factory exterior shall be kept in good repair as to
protect against the entrance or harboring of insects or
birds or vermin; external drainage pipes and ventilation
fans shall be designed to prevent such kind of infestation.
• Factory shall be preferably designed to possess
single designated point of entry for raw material
reception, for personnel, and for the delivery of finished
products; otherwise it shall be compensated by a time
schedule.
• Raw material access and product delivery exits
shall have a buffering areas or double doors in order to
protect warehouse from environment contamination.

15
 5.1- Internal factory layout
The factory building shall be internally designed to
comply with the following:
• The factory should be sufficient in size for the
purpose intended without crowding of equipment or
personnel;
• Areas where raw material such as raw sesame seed
and salt are received or stored should be so separated from
areas in which final product preparation or packaging is
conducted as to avoid possible cross contamination of
the finished product.
• Areas and compartments used for storage,
manufacture or handling of edible products should be
separate and distinct from those that are used for inedible
material.
• The food handling area should be completely
separated from any part of the premises used as living
quarters.

5.2- Building structure

• Floors, walls and ceilings and doors shall be made
in a manner to facilitate easy cleaning.
• Wall and ceiling surfaces shall be smooth, free from
cracks or damages. Walls shall be light in color consisting
of tiles or polymer coatings capable of withstanding hot
water and detergents. All junctions must be well sealed.
If needed walls should be protected using guard rails in
order to reduce the maintenance frequency.

16
 • Warehouse floors shall be covered with coatings or
mixtures to avoid dust emissions. Production area floors
such as sesame peeling and washing areas, where water
and steam might be frequently utilized shall be covered
with polymer type coating or tiles that are impervious to
moisture and resistant to chemicals and food material.
Whenever appropriate, angles should be coved to avoid
contamination and facilitate cleaning. Floors should also
be sloped for water to drain towards trapped outlets or
channels in order to eliminate or reduce the possible
retention of water and static water pools.
• Metallic structures or columns shall be made from
corrosion free steel or painted with non-corrosive food
safe coating.
• Externally opening windows in or close to the
production area should be effectively screened to prevent
the ingression of flying insects; Preferably there should
be no glass in the production area; If glass is present it
should be shatterproof or coated with shatterproof
film; Wherever possible, glass should be replaced with
toughened plastic.
• All doors should be tight fitting and pest proofed.
External doors directly opening into the production
area should be avoided, where they exist they should
be screened or self-closing doors should be of good
condition and easy to clean.

5.3 Material and personnel flow

• Production lines and product flow should be
designed to have a ‘linear flow’ from raw material to

17
 finished product and an identification of the low risk and
higher risk areas be established.
• A factory plan should be established whereby the
physical separation of the low risk areas from high risk
areas is reviewed and confirmed. It should also include
movement of factory staff from the entrance to their work
place.
• Where there is a transfer of product from low risk
to high risk activities, care should be taken to ensure
practices are in place to minimize the risk of contamination
• Careful consideration should be given to the
control of packaging material.
• In the production of Tahina: Raw sesame cleaning
and peeling (low risk products) shall be separated from
roasting of peeled sesame (high care) and grinding of
roasted sesame (high care).
• Staff working in the cleaning and peeling of
sesame shall not pass in the areas of roasting and grinding.
Measures should be taken before the entrance to those
areas to reduce contamination of the area by unclean
staff.
• In the production of Halawa: the preparation of
Natef (low risk) should be separated from the preparation
and filing of Halawa (high care).
• Measures shall be taken prior to the entrance
of the Halawa preparation and filling areas to reduce
chances of contamination by staff.

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5.4- Equipment
• All equipment should be designed and installed
in a manner allowing easy access for visual examination
and cleaning and where appropriate to be dismantled in
order to allow integral parts to be cleaned and disinfected.
All food contact surfaces must be smooth, seamless and
scratch free; inert to food products.
• Where appropriate, equipment is properly drained
and connected directly to drains.
• System must allow good housekeeping practices
i.e. ‘clean as you go’
• Equipment having direct contact with food shall
be accompanied with technical documents or supplier
declaration showing compliance with food contact
material legislation.
• Whenever possible, parts of equipment which are
open to the general environment should be covered.

5.5- Containers for waste disposal

The systematic disposal of waste is critical to remove
material that could potentially contaminate safe product.
• Internal waste containers should be clearly
identified in specific areas of the factory inside the
production and packaging areas; designed to be easily
cleaned; do not leak and are designed to be disinfected
whenever possible and covered to minimise risk of
contamination.

19
 • External waste storage areas should be remote
from the main factory buildings, should be kept as clean
as possible and included in the site cleaning program;
should be protected from pest ingression, removed from
the site /or emptied at predetermined frequency.

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 6- FACILITIES

6.1- Water and steam supply

An adequate supply of potable water with appropriate
facilities for its storage, distribution, and temperature
control should be available whenever necessary to ensure
safety and suitability of food.
• Potable water must come from an approved
source, either through a municipal supply or private well;
and should be as specified in the latest edition of LIBNOR
NL 161/2001.
• In case of the presence of non-potable water
system to be used for cleaning purposes or firefighting,
it shall be clearly identified and shall not connect with, or
allow backflow into, potable water systems.
• Water recirculated for reuse, if available, should be
treated and maintained in such a condition that no risk
to the safety and suitability of food results from its use.
The treatment process should be effectively monitored.
Recirculated water can only be used without treatment,
provided it doesn’t constitute a risk to the safety or
suitability of food.
• Only potable water should be used in food
handling and processing, except if it is used for steam
production, provided that steam is not used in direct
contact with the food.

21
 • The water supply must be constructed, properly
maintained and tested routinely to ensure safety. In
general, wells must be tested at least once per year. Water
testing frequency needs to be based on a risk assessment.
(Depending on the original contamination of the well and
on the risk of contamination).
• In case of non-availability of potable water source,
a water treatment system shall be applied. (Sand filtration,
chlorination, charcoal filtration, reverse osmosis, ion
exchange, or others).
• Hot and cold potable water must be available in
all processing areas which can be used for better cleaning
and adequate hand washing.
• Sufficient volume and water pressure must be
available to dislodge particles sesame or sugar film from
surfaces of cooking or roasting equipment. A high-
pressure washer is highly recommended.
• Plumbing systems must be installed and
maintained according to construction laws (well sized
and designed). It shall be identified (by color) for potable
water, non-potable water and for steam.
• Adequate cross connections shall be installed
between a potable and non-potable source through
which backflow can occur; and a regular monitoring of
such a system.
• Proper Air breaks shall be used for all plumbing
connected to a drain to avoid backflow.

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6.2- Drainage and waste disposal
• The factory drainage system shall be designed
and constructed to prevent cross-connection between
the effluent of human wastes and any other wastes in the
establishment.
• No drainage pipes pass directly over or through
production areas, unless they are controlled to prevent
cross contamination.
• Drainage systems inside the production areas
for sesame processing and halawa manufacture shall
be shallow and sloped towards the main water trap. All
Drainage and sewage systems should be equipped with
appropriate traps and vents.
• Facilities are provided for the storage of waste
and inedible material prior to their removal from the
establishment. These facilities are designed to prevent
cross contamination.
• Waste from production and storage areas should
be removed to designated waste storage areas at a
predetermined frequency; it should not be accumulated
in food handling areas and the adjoining environment
except so far as is unavoidable for the proper function of
the food business.

6.3- Cleaning
• A separate facility should be provided for cleaning
and sanitizing of equipment used for inedible material.
• Potable water should be provided at temperatures
appropriate for the cleaning chemicals used.

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 • Cleaning equipment is adequately separated from
food storage, processing and packaging areas to prevent
contamination.

6.4- Personal Hygiene facilities

• Designate adequate and cleaned dressing areas
or clothes/shoes storing and changing areas for workers.
• The provision of an adequate number of hand
washing facilities with running water at the suitable
temperature; located at the entrances of process areas
and strategic locations other than washrooms such
as : before entering the sesame processing area; the
Tahina filling area; the sesame roasting area; the Halawa
preparation and filling area.
• Washrooms also should have hand washing
facilities with a sufficient number of maintained sinks that
are properly trapped to drains. Hand washing facilities are
adequately maintained and have hot and cold running
potable water, soap, sanitary hand-drying supplies or
devices, and, where required, a cleanable closed waste
receptacle as well as self-closing doors. Washroom
fixtures, such as water control valves, should be preferably
of a type designed to protect against recontamination of
clean, sanitized hands.
• Post easily understood signs directing employees
to wash and, if appropriate, sanitize their hands before
they begin work, before returning to work from a break
and any time their hands may have been contaminated .

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 • Washrooms, toilets, lunchrooms and change
rooms and toilets, are adequately ventilated and
maintained (adequate floor drainage); they should be
located separate from and do not lead directly into food
processing areas.
• Toilet facilities shall be adequate and readily
accessible; shall be kept clean and in good repair. Basins
shall be sanitized at least twice per shift; doors self-
closing.

6.5- Temperature, air quality and ventilation.

Tahina production can take place under ambient
temperature conditions provided adequate air ventilation
takes place in various areas:
• The dry sesame pre-cleaning areas shall be
ventilated to remove dust transmitted from the cleaning
operation which can cross contaminate other areas and
personnel.
• The roasting area shall be ventilated to remove
excess steam. Good ventilation is important to prevent
condensed water dripping into the dry product and
mold growth in overhead structures - which may result
in foreign debris falling into the food; as well as raise the
working temperature of the area to unacceptable levels
especially during summer.
• The roasted sesame grinding area should be well
ventilated in a manner to assure a clean air environment
free from fine dust particles; especially when grinding
stones are being utilized.

25
 • Tahina packaging area should be ventilated with
filtered clean air in order to reduce risks of contamination
during the filling of Tahina into retail/bulk recipients.
Halawa production can take place under ambient
temperature conditions provided adequate ventilation
takes place; it is recommended that the Halawa filling
and closing areas to be air conditioned in summer when
temperatures in the room might exceed 30 degrees C.
• Natef production area, especially when traditional
open beater system is utilized, requires removal of excess
steam in the environment in order to reduce chances of
contamination.
• Halawa preparation and filling area shall be
supplied with filtered clean air free from fine dusts
or particles that could contaminate product during
preparation and while filling. (ISO 14644-1 1999 can be
used as a standard.)

6.6- Lighting
• Premises should be well lit, especially in the
material storage areas, inspection areas, and areas that
are not easily accessible or are difficult to clean.
• Light bulbs and fixtures suspended over food in
any step of preparation should be of the safety type or
otherwise protected to prevent food contamination in
the case of breakage.
Codex Recommended standards for lighting:
- 550 lux (50 foot candles) at inspection points

26
 - 220 lux (20 foot candles) in work rooms
- 110 lux (10 foot candles) in other areas.

6.7- Storage
• Incoming material should be handled and stored
in conditions that prevent damage and/or contamination.
(Clean warehouse, on pallets, away from walls, adequately
ventilated, adequate pest management).
• Incoming material storage should always be
separated from production premises.
• Non-food chemicals are stored in designated areas
such that no possibility exists for cross-contamination of
food or food contact surfaces.
• Finished product warehouse shall be separate
from primary material storage and adequately ventilated.

27
 7- PROCESS CONTROL

The objective is to produce Tahina and Halawa which is

safe and suitable for human consumption, by controlling
process measures at all stages in the operation. Control
procedures must be defined and described throughout
all the food chain.
7.1- Process flow charts
Hereafter are described the process flow charts for:
1- Tahina as produced traditionally which still covers
the majority of producers in Lebanon
2- Tahina continuous (automated) production line.
3- Halawa traditional process.

29
 7.1.1- FLOW CHART TAHINA TRADITIONAL BATCH PROCESS

TRADITIONAL TAHINA PRODUCTION PROCESS FLOWCHART

RECIPIENTS RAW COARSE POTABLE

TAHINA SESAME SALT WATER

Dry Pre-cleaning
of Sesame seeds

Washing of
sesame seeds Low Care
Areas

Soaking of
sesame seeds STEAM

Inspection and
cleaning Peeling of sesame
seeds

Peel Seperation

Desalting of
peeled seeds

Dewatering of the
seeds

Roasting

Cooling

High Care
Areas
Grinding

Weighing and
storage of tahina
Corrugated
cartons
Heat treatment for
tahina

Filling of tahina packing delivery

30
7.1.2- FLOW CHART TAHINA CONTINIOUS PROCESS

CONTINUOUS TAHINA PRODUCTION PROCESS FLOWCHART

RECIPIENTS RAW COARSE* POTABLE

TAHINA SESAME SALT WATER

Dry Pre-cleaning
of Sesame seeds

Peeling of sesame
STEAM
seeds
Low Care
Area

Peel Seperation

Inspection
and cleaning Wetting of the
seeds(30%
humidty)

Drying of the wet

sesame seed
(12%)

Roasting(<1%
humidity)

Cooling and
classifying

Grinding
High Care
Area
Weighing and
storage of tahina

Heat treatment for

tahina Corrugated
*Opitonal for cartons
some producers
for taste purposes.
Filling of tahina Packing Delivery

31
 7.1.3- FLOW CHART HALAWA TRADITIONAL

TRADITIONAL HALAWA PRODUCTION FLOWCHART

RAW WHITE HALAWA ROOTS/

TAHINA FLAVORS CITRIC WATER
SUGAR EMULSIFIER

Root Extract
Root washing
Preparation
Pre-heating
tahina

Low Care
Area

Preparation of aerated sugar

Weighing of sugar
NATEF

Weighing of
Preparation of the Halawa mix
Tahina

STEAM

Portioning of the halawa

Empty jars and Visual

Filling of the Halawa
covers Inspection

High Care
Area
Corrugated
Packing of halawa
Carton/trays

Storage and delivery

32
7.2- Microbiological, physical and chemical
contamination
Production processes for Tahina should be established
and implemented in a manner to prevent and control
all potential hazards emanating from a microbiological
source (B); a physical source (P) and a chemical source
(C). A hazard analysis table located at the end of this
document has been prepared for Tahina and Halawa
based on the flow charts described above.

7.3- Reception and storage of incoming Material

• All incoming raw and packaging material shall be
inspected upon reception for quality compliance with
required specifications either through sensory analysis or
by laboratory testing or through the provision of eligible
supplier certificate of analysis or supplier audits.
Material relevant to the production of Tahina and
Halawa are: Sesame seed, Sugar, Salt, Natural Halawa
roots, chemical emulsifiers and essential oils.
• Documents identifying raw material specifications
should be held by the establishment. Those specifications
relating to Physical, chemical and microbiological
parameters, such as percent of foreign matters, percent
moisture, color, size, microbiological criteria, toxins,
purity, packaging and hygienic parameters.
• Documents identifying packaging material
specifications should be held by the establishment.
Those specifications relating to hygienic parameters

33
 and approved food contact material. Packaging
material relevant to the packaging of Tahina and Halawa
production are plastic (PE, PP, PET) jars/boxes with their
cover, printed flexible films, plastic or metallic buckets,
glass jars.
• All incoming non-food chemical material such
as detergents, disinfectants, pesticides shall be stored in
closed areas, separate from food ingredients or essential
oils and accessible only by authorized personnel.

7.4- Storage and Delivery of semi-Finished product

• All Tahina produced after the sesame grinding
shall be directly stored in closed, clean, dry and inert
containers or tanks (Stainless steel is recommended)
before packing.
• Bulk Tahina is stored under adequate temperature
conditions preferably< 35 degrees C.
• Tahina is regularly agitated to avoid sedimentation.
• Tahina shall be discharged from the tanks through
clean valves and pipes to the Tahina packing station or for
Halawa production without any contact with personnel
or contaminated accessories.

7.5- Storage and delivery of finished product

• Finished products are stored and handled under
conditions that prevent their deterioration.(clean
secondary packaging, clean warehouse, adequate
ventilation)

34
 • Stacking of the finished products shall be on pallets
in a manner that protect them from contamination and
from over stacking. Products shall be clearly identified by
name, date of production and a lot number.
• Samples from each lot are taken for sensory,
chemical and microbiological laboratory testing.
• A procedure for finished products shall be
established to assure it is not released for external
commercialization without lot inspection by an
authorized and qualified person.
• Daily records of stock testing and stock rotation
shall be kept.
• Returned, defective or suspected goods are
controlled, clearly identified, and isolated in a designated
area until they can be disposed appropriately.

7.6- Quality of the Water as an ingredient

• All water utilized in the processing of sesame
seed must be of potable quality water, unless it has been
treated for a specific intended use. (Highly chlorinated
water, de-ionized water,).
• Water used in the process (soaking, cleaning,
desalting, wetting of the sesame) shall be tested on
a daily basis to assure it complies with potable water
conditions. The type of tests shall depend on the level of
treatment it undergoes and on the original source of the
water. Microbiological tests might not be needed on a
daily basis but should be performed on a regular basis to
verify the performance of the treatment.

35
 • All personnel handling water for process shall
comply with sanitation and hygiene standard of the
factory.
• Procedure for the maintaining clean potable water
in the factory shall be established.
• Records on the sanitary status of the water shall
be kept.

7.7- Production management and hygienic

p a ra m e te r s
Production management procedures shall insure that
Tahina and Halawa are produced in respect to required
raw material and finished product specifications including
food safety requirements.
• All staff working in the production of Tahina and
Halawa shall receive clear tasks and responsibilities, and
shall be sufficiently qualified and trained on the process
control and especially on the corresponding food safety
parameters.
• All task descriptions should be documented and
well understood by the persons in charge. Evidence of
the qualifications shall be kept (Academic Qualifications,
experience, training, history or other).
• Control of the operation should be done in
respect to parameters related to the processing such as
quality of the peeling, density of the salt solution, time
and temperature of roasting, moisture content of the
Tahina, viscosity after grinding, color of the Tahina; time

36
and temperature for processes relying on heat treatment
of the final product. For Halawa: Density of the Natef,
weight of the product, hygiene of the workers, Records
shall be kept for that purpose.
• Procedures should be in place to prevent
contamination of foods by foreign bodies such as glass,
metal shards, flaking paints, and unwanted chemicals or
fumes.
• All filling hoppers, elevators, open food belt
conveying should be protected against overhead
contamination. (Example roasters, hoppers of the
stone grinders, post grinding sifter belts, Tahina filling
conveyors, Halawa mixing, Halawa filling).
• As far as possible wood and wooden containers
and pallets should be eliminated from food production
areas. It could be replaced by stainless steel or food grade
plastic material which do not absorb food residues and
are easily washable.
• Production managers/supervisors/foremen shall
insure that all operators and workers are aware and follow
hygienic procedures related to equipment cleaning,
process and personnel sanitation.
• Primary and secondary Packaging of the Tahina
and Halawa must be adequate to provide protection of
the food products, minimize contamination and prevent
damage. The packaging operation shall ensure that all
material utilized such as food contact material, type of
glue, staples, shall not increase the risk of hazard.

37
 • All staff operating in the packaging section shall
be well trained on the adequate handling of the food
product during the packaging operation and on the
hygienic requirements of the material which can come in
contact with the food product. All staff shall comply with
the personnel sanitation procedures established.

7.8- Quality assurance and quality control

Monitoring of the application of good manufacturing
practices, cleaning, online inspection and final product
testing shall be applied whenever relevant in order to
verify that the GMP requirements as well as the product
specifications as required are being implemented in a
satisfactory manner.
• Validated Sampling and testing methods shall be
established to inspect raw material, finished product and
on line parameters for Tahina and Halawa.
• Tests related to food safety are microbiological
tests including total viable count and Salmonella;
chemical tests including moisture tests and Aflatoxin
tests; physical tests including filth determination.
• Adequate laboratory facilities shall be installed
in order to perform all scheduled food safety tests; it
includes a microbiological unit. In case of absence of a
complete factory laboratory, outsourcing of laboratory
services shall be undertaken preferably with laboratories
accredited for the microbiology tests and Aflatoxin.
• Inspection plans for personnel sanitation, factory
sanitation and equipment sanitation shall be established

38
to verify the application of the GMP procedures. Inspection
procedures shall be established and inspection records kept.
• On line inspection of processes and application
of hygienic practices shall be performed and non-
conformities reported.
• Quality control and laboratory personnel shall
be qualified and trained to perform the tasks at hand.
Evidence of qualifications shall be presented.
• Quality records shall be generated and kept.

7.9- Record keeping

All quality records pertaining to food safety shall be
kept.
• Forms for the reception and laboratory inspection
of raw material, delivery and laboratory inspection
of finished product, on line inspection of production
processes, process parameters, personnel hygiene,
implementation of cleaning schedules, food safety
complaints, personnel training or other food safety
related issues shall be established.
• Records shall be kept with designated staff for
relevant periods at least the time exceeding the shelf life
of the Tahina and Halawa or as requested by the local
regulations.

7.10- Traceability and Recall

• Documentation associated with the product
coding system should be established. For traceability

39
 purposes Tahina and Halawa products should be identified
with a production date consisting of a production day,
month and year or code that identifies each lot. The
product coding system should allow the establishment to
trace raw ingredients, batch number, packaging material
and finished products.
• Records documenting all complaints related to
Tahina and Halawa safety and the actions taken should
be filed.
• Recall procedures for notifying affected customers
should be established; depending on the type and severity
of the hazard the communication (fax, telephone, letter,
or other means) shall be selected to be used to trace back
effectively and quickly all affected product.
• Within the recall procedures, procedures to
withdraw the product from the market as quickly as
possible should be established, the amount of recalled
product involved in addition to the remaining quantity
in the company’s possession after distribution should be
compared with the total quantity produced.
• Control measures shall be taken to isolate returned
products in the establishment warehouse after a recall to
avoid a cross contamination issue prior to its destruction.
• Production and distribution records should be
maintained in order since it allows the establishment
in the event of a recall to locate effectively all products.
Recall and production records are kept for a period of
time that exceeds the shelf life of the product.

40
 8- MAINTENANCE AND SANITATION

• The Tahina and Halawa factories and the

equipment used for its production should be kept in good
conditions in order to facilitate all sanitation procedures;
function as intended, and prevent contamination of food,
e.g. from metal shards, flaking plaster or paint, debris and
chemicals.
• Cleaning of premises and equipment should
remove food residues and dirt which may be a source
of contamination. Disinfection is recommended after
cleaning.

8.1- Equipment and tools

• The factory should implement an effective
written preventive maintenance program to ensure that
equipment that may affect food quality is maintained
in proper working order. The preventive maintenance
program should be followed and should address as
a minimum sesame peeler, sesame roasters, sesame
grinding stones, sesame grinding machine, Tahina
filler, plastic jar sealer, Halawa box sealer, and any other
equipment or tool affecting the food safety.
• Equipment should be maintained to ensure the
absence of any physical or chemical hazard potentials,
e.g. flaking paint, rust and excessive lubrication.

41
 • All surfaces including their joining must be
smooth, and must have neither ridges nor crevices which
could harbor organic material; Lubricants used for food
manufacture should only use food grade lubricants.
• Parts of the equipment where product is open to
the atmosphere should be covered to prevent foreign
matter falling into the product area.
• Machinery must be designed and constructed as
to prevent any liquids, organic matter or living creature
(including insects), entering or accumulating in areas that
cannot be cleaned (e.g. for machinery not mounted on
feet or casters, by placing a seal between the machinery
and its base, by the use of sealed units, etc.);
• All equipment must be designed to withstand
alkaline washing solutions and hosing.
• Measuring and monitoring devices that affect
food safety such as thermometers, weighing scales, pH
meters, humidity meters or any others specific tools must
be calibrated (evidence of conformity) to ensure that
readings are precise and consistent. Records of calibration
process shall be kept. SOP for the calibration of various
tools should be established.
• Cleaning chemicals should be handled and
used carefully and in accordance with manufacturers’
instructions.

42
8.1.1- Special requirements for some Tahina and
Halawa equipment:
• Sesame peeler:
- All products in contact with food shall be in food
grade stainless steel. (Type 304 or 316).
- All surfaces must be safely accessible for cleaning
and for visual examination as manual cleaning is carried out.
• Sesame roaster :
Prevailing Batch roasters:
- Material in contact with the food shall be made of
inert material; non-corrosive; preferably stainless steel.
- Gears, couplings and motors responsible for reducing
the speed of the scrapers as well as creating the pendulum
movement, shall be so designed and constructed that
no ancillary substances (e.g. Lubricants, etc.) can come
into contact with sesame seeds inducing chemical
contamination.
- Roaster shall be designed in a manner to facilitate
discharge of the roasted sesame without spillage or
leakage.
Continuous batch roasters:
- Material in contact with food shall be of non-corrosive
inert material.
- Machine should have easy access for cleaning of the
roasting components.

43
 • Grinding stones
- Stones shall be made of food inert material
- Gears and couplings shall be designed not to initiate
any grease or oil dripping in the food contact areas.
- Tahina receiving troughs located around the stones
and feeding it into the bins shall be made from stainless
steel.
- Part of the stones where Tahina flows shall be covered
with stainless steel.
• Tahina storage bins
- Shall be manufactured from stainless steel or other
food inert material.
- Shall be equipped with a sanitary discharge valve
that does not allow stagnation.
- Shall be covered.
- shall possess a fine sifter at the feeding entrance to
prevent any physical contamination to enter into the bin.
• Tahina filling machine
- All Tahina contact parts shall be made from stainless
steel
- Shall be designed to allow easy access to cleaning
with alkaline detergents.
• “NATEF” preparation machine
- Product contact material to be smooth without
scratches and from stainless steel.
- Machine easy to clean without sharp edges or corners.

44
 - Sanitary discharge valve to avoid product or water
stagnation.
• Halawa preparation tank
- Product contact material to be made from food grade
stainless steel.
- Malaxer to be made of stainless steel and should be
accessed/removable from all sides for cleaning.
- Electric motor and gear not to be hanging over the
food product.

8.1.2- Cleaning procedures (SSOP) and Programs.

• Tahina and Halawa producers should have a
written cleaning program related to the areas and
equipment to be cleaned; the frequency and the persons
responsible for cleaning. (What, when and who)
Areas to be cleaned on a daily basis are: Raw material
warehouse, production area, packaging area, laboratory,
restrooms rooms.
Area Frequency Type Person Verification
of cleaning in charge
Raw material daily Dry cleaning Cleaning Daily log
warehouse team
Tahina/Halawa daily Wet Cleaning Daily log
Production cleaning and team
areas disinfection
Packaging daily Dry cleaning Cleaning Daily log
area team
Laboratory daily Wet Cleaning Daily log
cleaning & team
disinfection
Restrooms Twice per Wet Cleaning Daily log
shift cleaning & team
disinfection

45
 Equipment cleaning schedule: example Tahina production
Equipment Frequency Type Person Verification
of cleaning in charge

Soaking daily COP; Wet Cleaning Daily log

tanks cleaning; team
detergent
Sesame peeler daily Wet Cleaning Daily log
cleaning; team
detergent
Sesame dryer daily Scrubbing; Cleaning Daily log
dry cleaning team
Sesame Every 20 hrs. Wet clean Person in Daily log
roasters with charge of
scrubbing/ roasting
sanitizing
Sesame According Dry cleaning Person in Log each
sifters to work with charge of time it take
intensity scrubbing/ grinding place
sanitizing
Sesame Every 3 Dry Person in Monthly
stone weeks or cleaning; charge of Maintenance
grinders whenever scrubbing; grinding. schedule
it looks burning;
necessary scrubbing;
depending sanitizing
on the
intensity of
work

• Cleaning chemicals should be handled and

used carefully and in accordance with manufacturers’
instructions and stored, where necessary, separated from
food, in clearly identified containers to avoid the risk of
contaminating food.
• Sanitation standard operation procedures or
SSOP on cleaning of premises should be established:
- Wet Cleaning of walls, floors, ceiling and drainage
areas.
- Wet cleaning of laboratory.

46
 - Dry Cleaning of warehouses for raw material and
finished products.
• Sanitation standard operation procedures or
SSOP on cleaning of equipment:
- Cleaning of soaking tanks and sesame peeler.
- Cleaning of sesame dryers.
- Cleaning of sesame roasters.
- Cleaning of sesame sifters.
- Cleaning of sesame grinders.(Annex 3 )
- Cleaning of sesame storage Tanks.
- Cleaning of Tahina filling line.

8.2- Pest Management

Good hygiene practices should be employed to avoid
creating an environment favorable to pests.
• Factory Building should be kept in good repair
and condition to prevent pest access and to eliminate
potential breeding sites Holes, and drains should be kept
sealed.
• Wire mesh screens, should be installed on open
windows, doors and ventilators.
• Areas both inside and outside food premises
should be kept clean. Where appropriate, refuse should
be stored in covered, pest-proof containers. Surrounding
areas should be regularly examined for evidence of
infestation.

47
 • Pest infestations should be treated with chemical,
physical or biological agents immediately and without
adversely affecting food safety or suitability; label and
store all pesticides and pesticide equipment separately
from oils and products used in food processing.
• Establish procedures or obtain from suppliers
documentation for chemical use to avoid over usage or
misapplication. Develop a training program and identify
employees with an authorization to apply chemicals.
(Annex 4 example of an SOP)

8.3- Waste Management

• Construct and maintain waste receptacles in ways
that protect against food contamination. (Recipients to
be covered, no leakage of liquids, designated areas).
• Waste must not be allowed to accumulate in food
handling, food storage, and other working areas and the
adjoining environment except so far as is unavoidable for
the proper functioning of the business
• Waste stores must be kept appropriately clean
and should be quickly disposed of in order to minimize
odor, and potential attraction of flies and other pests.
• Waste water shall be disposed of in municipal
sewers or collected in septic tanks far from factory
premises after the removal of the solid wastes.

8.4- Personnel Hygiene

Appropriate training on personal hygiene and
hygienic handling of food is provided at the beginning of

48
employment and is reinforced and updated at appropriate
intervals.
• All Personnel should always wash their hands
when personal cleanliness may affect food safety. For
example at the reception of packaging material for
Tahina and Halawa; at the beginning of any food activity,
immediately after using a toilet, whenever they need to
deliver food samples for testing, each time they move
from low risk area to a high risk area. (Example: if moving
from sesame washing and peeling area to the sesame
roasting area, or when moving from Natef preparation
to Halawa filling area). Note: Hand sanitizing does not
replace hand washing. An SOP should be prepared for
this purpose: see Annex 2.
• It is recommended that all working personnel
working in the high care areas of the factory to sanitize
their hands after washing them and wear clean shoes
prior to entering the area.
• Protective clean clothing and hair covering should
be worn in almost all areas of the Tahina and Halawa
factory. It is advisable that workers operating in low
care areas to wear different colors than those operating
in a high care areas to avoid cross contamination due to
personnel.
• Jewelry, watches, pins or other personal items
should not be worn or carried into food handling areas.
• Tobacco, gum and food are not permitted in food
handling areas.

49
 • Visitors must adhere to the same personnel
hygiene rules and notices are posted at the entrance of
the food preparation area.
• Employees who exhibit infected wounds, skin
infections, sores or discharges from the eye and nose are
prohibited to work in food handling area unless the injury
is completely protected by a secure waterproof covering
• Employees who suffer from diarrhea,
communicable disease (hepatitis or jaundice) or known
to be a carrier of a disease likely to be transmitted through
food are not permitted to work in food handling area.
• Medical records for employees should always be
kept and regularly checked.

50
 9- TRANSPORTATION

Food must be adequately protected during transport;

while transportation tools shall be adequate for the
products they carry.
• Tahina obtained from the grinders shall be
transported in corrosion free washable inert metal
containers /bins or food grade plastic containers. Bins
shall be designed to have a smooth surface and to
minimize difficult to clean sharp corners as well as utilize
non-drip valves.
• Finished product shall be transported in clean
trucks.
• Effective cleaning and, where necessary,
disinfection of the containers should take place between
loads in designated areas near the receiving yard.
Containers used for transporting food should always be
kept in an appropriate state of cleanliness, repair and
condition.
• Inspect bins for damages on a regular basis
and repair or discard damaged containers and repair
immediately those damages that might induce
contamination.

51
 10- PRODUCT INFORMATION
AND CONSUMER AWARENESS

• Lot identification is essential in product recall and

also helps effective stock rotation. Each container of food
should be permanently marked to identify the producer
and the lot. Codex General Standard for the Labeling
of Prepackaged Foods (CODEX STAN 1-1985, Rev. 2010)
applies.
• Tahina and Halawa products should be labeled
with clear instructions to enable the next person in the
food chain to handle, display, store and use the product
safely. The fact that Sesame seed is an allergen shall be
clearly indicated on both Tahina and Halawa labels.
Ingredients shall also be clearly mentioned especially if
additives or coloring agents such as Titanium dioxide are
being used. Codex General Standard for the Labeling of
Prepackaged Foods (CODEX STAN 1-1985, Rev. (1991))
applies.

53
 11- TRAINING

• All personnel handling raw material and finished

product should be aware of their role and responsibility
in protecting food from contamination or deterioration.
• Personnel handling strong cleaning chemicals
or other potentially hazardous chemicals should be
instructed in safe handling techniques.
• Training programs shall take place on topics relate
to sesame handling, food contamination, food storage,
and the parameters for maintaining the shelf life of Tahina
and Halawa.
• Periodic assessments of the effectiveness of
training and instruction programs should be made, as
well as routine supervision and checks to ensure that
procedures are being carried out effectively.
• Training programs should be routinely reviewed
and updated where necessary.
• Records for employee training should be
maintained.

55
 12- HAZARD ANALYSIS FOR TAHINA
No. 1- Ingredients/process step 2- Identify potential hazard introduced, 3- Is hazard 4- Reason 5- Control measures
controlled or enhanced at this step significant? for Column 3 for the hazard
(Yes/No)
1 Raw Sesame seeds received Biological B- Y B- B1&B2
1- Presence of Salmonella & other gram 1&2 .Historical data. - Storage and Raw material
negative pathogens. reception procedures.(GMP)
2- E-Coli. - Pre-cleaning step.
Physical P- Y P- - Roasting step.
1- Sand & Stones. 1- Related to the raw P1
material specifications. - Pre-cleaning Step.
Chemical C- N C-
1- Pesticide residues. 1- No record of high C1-NA
2- Aflatoxins exceeding 10ppb. level of pesticide or
unapproved pesticide C2- Material reception and
residues found in testing procedures.(GMP)
sesame. Codex did not
specify MRLs.1

2 Sugar received Biological B- N B- B-

1. Presence of thermophile spoilage No historical records Suppliers’ analysis certificate.
organisms. showing thermophile p-
contamination in Visual inspection (GMP)
sugar.
3 Salt received Physical P- Y P- P-
Physical impurities due to low quality salt History of use of low - Inspection of incoming raw
utilized. quality salt stock for material.
the step. - filtering the brine solution.

1- According to FDA Pesticide monitoring program 2008, 82% of sesame seed samples tested had no pesticide residues and those who had were within the limits and 100% of sesame paste samples
(Tahina) had no residues. In the 2011 monitoring program, 100% of samples of sesame seed and Tahina had no pesticide residues.

57
58
No. 1- Ingredients/process step 2- Identify potential hazard introduced, 3- Is hazard 4- Reason 5- Control measures
controlled or enhanced at this step significant? for Column 3 for the hazard
(Yes/No)
4 Water utilized Biological B- B- B-
1- Survival of E-coli. Y 1- Frequent in water 1. Appropriate water treatment
2- Survival of Pseudomonas Y that are from wells. and testing system.
aerugenosa. 2- frequent in water or 2. Roasting step in the process.
3- Presence of other organisms such Y municipal water that
as vibrio cholera; hepatitis A, have been stored for a C-
Salmonella. long period before use. 1. Appropriate water treatment
C- Chlorination being system. Charcoal filtration.
C- N widely used as a P-
1- High Chlorine residues if the water decontaminant in 1-Adequate water filtration
treatment is based on chlorine. water. system. (UV sterilization
P- Frequently found immediately before use).
Physical P- in turbid waters
1- Sand . from wells or stored
municipal waters.

5 Pre-cleaning of sesame seed Physical P- P-

1- Stones and sand. Y Found in almost all Sifting/cleaning of the sesame
types of raw sesame. during the pre-cleaning step.

6 Washing of raw sesame seed Water (Same as step 4) Y Same as step 4 Same as step 4

7 Soaking water Y Same as step 4 Same as step 4

8 Peeling traditional water Y Same as step 4 Same as step 4

 No. 1- Ingredients/process step 2- Identify potential hazard introduced, 3- Is hazard 4- Reason 5- Control measures
controlled or enhanced at this step significant? for Column 3 for the hazard
(Yes/No)
8a Peeling continuous None

9 Peel separation None

9a Peel separation continuous None

system.

10 Desalting of peeled sesame water Y Same as step 4 Same as step 4

seeds

11 Dewatering of the desalted none

peeled sesame seeds

11a Partial Drying of the peeled Biological B- N - No records showing Filtration system in the area
sesame seeds - Potential Increase bacterial count impact on final should assure relatively clean
due to bacteria carried from the air product. air.(GMP)
dryer. - Roasting step should eliminate
any mild contamination.
12 Roasting of the dried seeds Biological B- Y B- B-
- Survival of Potential Salmonella 1-Historical data - Monitoring of the roasting
contamination from raw material. shows that salmonella process. Time vs temperature.
C- N has been detected in C-
- Target moisture content not reached. the raw material. - Achievement of adequate
moisture content levels.

59
60
No. 1- Ingredients/process step 2- Identify potential hazard introduced, 3- Is hazard 4- Reason 5- Control measures
controlled or enhanced at this step significant? for Column 3 for the hazard
(Yes/No)
13 Fine cleaning B- Y B- - Apply adequate maintenance
Bacterial contamination from badly Considering the post and cleaning of the sifters,
maintained or cleaned sifter. roasting step and as - Apply regular swab tests to
a result of human verify hygienic level.
improper handling. - Apply GMP sanitation
procedures on personnel.
14 Grinding(Stones) Biological B- B-
1- Contamination from badly Y Historical data shows Optional mild heat treatment
maintained or cleaned stones. increase in bacterial of Tahina before filling to
Increase bacterial count. count between the reduce total counts if exceeding
2- Contamination from pests on idle Y roasting operation National standards.(LIBNOR
stones during night time. and the grinding 71/2002 rev 2012)
3- Contamination from human Y operation. - Maintenance and cleaning
handling. procedures for the stones.(GMP)
- Pest management system.
Physical P- P- (GMP)
1- Stone powder emanating from the N No records showing - Apply personnel hygiene
grinding stones. product being procedures.
2- Remains from pests or insects. rejected neither as P-
a result of physical - Fine wire-mesh to filter Tahina
contamination nor prior to storage and before
as a result of % ash filling.
content. - Adequate maintenance of
stones.
- Adequate pest management
system. (GMP)
- Covering of the stones with
clean covers when idle.(GMP)
14a Grinding ( mechanical) Same as step 14 Same as step 14 Same as step 14
 No. 1- Ingredients/process step 2- Identify potential hazard introduced, 3- Is hazard 4- Reason 5- Control measures
controlled or enhanced at this step significant? for Column 3 for the hazard
(Yes/No)
15 Storage of semi-finished Tahina. B- B- B- & P
- Potential contamination from dirty or Y - Lack of awareness or - Procedure for the
contaminated bins, or wet bins. (Not well negligence . maintenance and cleaning of
dried after washing). Tahina storage tanks.
P-
-Potential contamination from dirty or
dusty bins.

16 Sterilization(optional) B- B-
Re-contamination of the Tahina post Y Records show that - Decontamination process to
roasting to a level unacceptable by LIBNOR Microbial quality reduce level of microorganisms
standard 71/2012. of some Tahina is by a mild heating of the Tahina
still below standard >70 degrees c.
requirements.

17 Plastic recipients received.(all B- Considering that B-

sizes) - Cross contamination of the recipient s due Y products do not -Following material reception
to bad handling from supplier till factory receive any treatment procedures.(GMP)
stores. post filling. C-
C- Supplier’s certificate That plastic
Recipient produced from material not recipients are made from food
approved as a food contact material. contact approved polymers.
(GMP)

61
62
No. 1- Ingredients/process step 2- Identify potential hazard introduced, 3- Is hazard 4- Reason 5- Control measures
controlled or enhanced at this step significant? for Column 3 for the hazard
(Yes/No)
18 Filling/Closing of Tahina B- B- B-
- Increase in the total count.
- Potential contamination from Y - Bad wrapping and - Procedure for the Reception of
contaminated packing material. handling of empty packing material.(GMP)
- Salmonella contamination or plastic recipient.
staphylococcus .
- Potential contamination from Y - Unclean human hands. - Hygienic behavior of workers.
contact with human handling. (GMP)
P- P-
- Potential contamination from Y - Risk of contamination - Covering areas over exposed
uncovered areas. of exposed food food. (GMP)
- Potential contamination from plastic Y product. - Procedure for the reception of
jars and /or plastic covers. - Dirty covers. packaging material.
19 Labeling of the recipients C- C- C-
Non-declaration of allergen. N - Tahina being made - Adequate labeling.(GMP)
100% from sesame.

20 Putting closed jars into cartons None

or trays.

21 Storing at ambient B- B-
temperatures. - Survival of thermophiles if Y - Hot summers in Always store Tahina and
temperature exceeds 45 degrees for Lebanon and bad moderate temperatures. (GMP)
a long time. storage habits of
- Increase of bacterial count if Tahina.
temperature exceeds 35 degrees C
for a long period.
 13- HAZARD ANALYSIS FOR HALAWA
No. 6- Ingredients/process step 7- Identify potential hazard introduced , 8- Is hazard 9- Reason 10- Control measures for the
controlled or enhanced at this step significant? hazard.
(Yes/No)
1 Tahina received Biological B- Y B- -Application or GMP on Tahina
1- Salmonella & other gram negative 1.Historical data. manufacturing.
bacteria. P-
Physical P- NA
1- Stones. Y C-
Chemical C- N 1. Not detected in
1- 1. Pesticide residues. unacceptable levels
sesame.

2 Sugar received B- B- B-
- survival of thermophiles. N - Historical data on - High temperature cooking
sugar contamination. step for sugar(Natef )
P- Y P- P-
- Impurities. - Possibility if sugar - Raw material reception
quality is not class procedure.
A or B.

3 Halawa Roots (Soapwort roots) B- B- B-

received - Contamination with bacteria some of - Natural status. Heat extraction of the saponin
which might be pathogenic. N in step 7.

P- P- P-
- Sand or soil residues. - Normal consequence. Washing of the roots prior to
extraction. Step 7.

3a Emulsifier received none

63
64
No. 6- Ingredients/process step 7- Identify potential hazard introduced , 8- Is hazard 9- Reason 10- Control measures for the
controlled or enhanced at this step significant? hazard.
(Yes/No)
4 Pistachios or other nuts B- Y - Historical evidence B- Procedure for receiving raw
- Salmonella. shows that pistachio material.
C- /nuts might be
- Aflatoxins or B1 toxins. contaminated with.
B-
- Salmonella.
C- Aflatoxin B1 toxins.

5 Water Same as step 4 in Tahina

6 Plastic recipients C- -Lack of awareness for C-

- Potential of being unapproved food Y approved food contact - Procedure for receiving
contact material. material. packing material.

P- P-
- Dirt and dust from bad handling. - Inspection and possibly
sanitizing of plastic recipients.

7 Preparation of Halawa extract B- -Natural presence of - Procedure for the preparation

- Microbial contamination. N microbes or dirt. of Halawa extract involves
P- washing and heating.
- Soil or dirt.

8 Preparation of Natef C- Limitations on natural - No existing limitations on

- Levels of Halawa root / or emulsifier. N as well as artificial Halawa root extract (saponin) in
food additives. Lebanon.
- Emulsifiers to follow Codex
food additive guidelines.
 No. 6- Ingredients/process step 7- Identify potential hazard introduced , 8- Is hazard 9- Reason 10- Control measures for the
controlled or enhanced at this step significant? hazard.
(Yes/No)
9 Preparation of the Halawa mix B- - Potential cross B-
- Contamination from the foreman Y contamination. Hygienic behavior of workers
responsible in the activity. (GMP)
C- C-
- Contamination from addition of new Y Procedure for the reception and
ingredients. testing of raw material.

10 Portioning of the Halawa B- - Potential cross Hygienic behavior of workers

Contamination from non-hygienic workers. Y contamination. (GMP)

11 Filling /Closing B- Y - Presence of unclean B-&P-

- Potential Contamination from packaging material. - Procedure for the reception
operator/workers. and testing of raw material.
- Potential contamination from
packaging material.
P-
- Potential contamination with dirt
from packaging material.

12 Labeling C- - Presence of sesame C-

- Non-declaration of allergen. Y paste. - Adequate labeling.

13 Putting in cartons None

14 Storing at ambient None

temperatures.

65
 ANNEX 1: FORMAT FOR
A STANDARD OPERATING PROCEDURE (SOP)

67
 ANNEX 2 : PROCEDURE:
HAND WASHING TECHNIQUES

Contaminated hands can also transmit infectious

diseases; therefore thorough hand washing before
commencing or returning to work is essential:
Frequency:
• Before starting or returning to work.
• after using the washrooms or bathrooms
• Before wearing gloves
• After eating or drinking or smoking.
• After working with raw sesame.
• After touching hair, nose, mouth.
• After handling garbage or waste.
• After handling any food allergen.
• Every time hands become contaminated.
Procedure:
1. Wet hands with clean water
2. Apply soap (preferably anti-bacterial)
3. Scrub hands and finger nails (for 20 seconds)
4. Rinse off soap thoroughly with clean water
5. Dry hands with single-use towels
6. Discard used towels in trash
Option when applicable:
7. Apply disinfectant whenever applicable.

69
 ANNEX 3: EXAMPLE OF AN SSOP

SSOP NO xxxx.: Cleaning of the traditional Grinding

stones.
Purpose: Cleaning and sanitizing of the sesame
grinding stones in order to reduce microbial
contaminants and keep machine in good working
condition.
Frequency:
Every day for routine check-up
once very month for complete breakdown of
machine for cleaning inside parts
Responsibility: Operator of the grinding stones;
production supervisor; production manager.
Tools and material needed: Strong plastic or
metallic brush; scrapers; cloth; squeegee, sanitizing
agents and alkaline detergents.
Procedure:
Daily cleaning:
1. Lift the upper stone to allow for internal cleaning.
2. Check if excess sesame remains are blocking
grinding channels. And clean lightly with a sanitized
brush.

71
 3. Remove any excess sesame particles or dust is
blocking the stone entry under the hopper.
4. Scrape any Tahina remaining in the Tahina canal
coming out from the stones.
5. Clean any Tahina residues on the exterior of the
stones with a clean sanitized scraper.
6. Make sure that the fine sifter at the entry of the
Tahina storage bin is regularly cleaned with a sanitized
cloth.
7.Make sure that the external structure of the
stone(metallic frame, and stainless steel chute ) are
wiped on a daily basis with a clean and sanitized cloth
in order to avoid any food remaining on the machine
for a long period.
8. Let the machine air dry.
9. Inspect if machine is now clean.
Periodic (Monthly ) cleaning
Based on factory experience and work intensity the
stones shall be maintained and cleaned thoroughly
on a periodic basis. Recommended every one month.
1. Call maintenance to lock out all electrical sources
and remove all access panels.
2. Make sure that the stone hopper is empty and
that the stone has been empty to the extent possible
without burning it.

72
 2. If it is not possible to remove the stone from the
grinding room then isolate the stone area from other
stones.
3. Remove the stone hopper and upper stone to
the highest position.
4. With the help of a clean and sanitized brush clean
thoroughly the inner surfaces of the stones to remove
any particulate matter or remaining food residues;
this should be done unit the internal stone grinding
tooth and product channels are clearly apparent.
5. Mist the surface of the stone with a sanitizing
liquid and keep it for a sufficient time until sanitizing
action can take place.
6. Let air dry.
7. Mist the internal surfaces of the stones (grinding
surface) with pure ethanol and let it burn. This should
continue the sainting process and assure a complete
drying of the stones.
8. Wipe all dismantled and frame connected parts
with detergent to remove any particulates and then
dry it well with a cloth and mist with a sanitizing agent.
9. Let it air dry,
8. Inspect machine to make sure all parts are clean.
10. Call maintenance to put machine back together.

73
 Corrective Action:
• If particulate matter is found on any area of the
machine upon inspection, repeat clean-up procedure
as detailed above for that particular area.
• If machine fails to start after weekly breakdown,
call maintenance. Do not attempt to fix machine!
Validation
• Apparent cleanliness and smell of the stones.
• Microbiological swab tests for total count and
survival of Salmonella.
Records
Logs showing cleaning schedule and validation
documents shall be maintained with production
manager.

74
 ANNEX 4 : EXAMPLE ON
SOP FOR PEST MANAGEMENT

SOP NO.XXX: Pest management

Purpose: reduce the risk of contamination by
rodents and other animals.
Responsibility: production manager, pest control
staff.
Pest control system
Establish a pest control program which should
include regular and frequent monitoring of affected
and treated areas to accurately assess the program’s
effectiveness.
Pest control procedures
• All procedures should be written and all
agrichemicals must be registered for use in food
handling establishments.
• Pest control procedures should describe the
location of any indoor or outdoor bait stations, glue
boards, and insectocutors. Indoor bait traps should be
placed every 3 to 4 meters and immediately on each
side of doorways – both inside and out. Outside bait
traps should be placed every 6 to 9 meters. Document
trap or bait station locations with a schematic map.

75
 • Include information on when placed, when
bait was replenished, and/or when the trap was
last checked. Make sure all stations are numbered
and types of trap(s) are described. Records of bait
disappearance and catches must be kept for each bait
station and trap. The insect control procedures must
be described.
• Maintain a pest control log that includes
dates of inspection, inspection report, and steps
taken to eliminate any problems. Establish frequent
monitoring of affected and treated areas to determine
the effectiveness of the treatment applied.
• Maintain the grounds in good condition.
Grounds in the immediate vicinity of all packing areas
should be kept clear of waste, litter, and improperly
stored garbage.
• Keep all grasses cut to discourage the breeding,
harboring, and feeding of pests, such as rodents and
reptiles. Remove any unnecessary articles, including
old and inoperative equipment that is no longer used,
to eliminate areas that harbor rodents and insects.
• Clean and sanitize daily to remove product or
product remnants that attract pests in and around the
packing facility and any other packing location where
product is handled or stored.
• Maintain adequate surface drainage to reduce
breeding places for pests and food contamination by
seepage.

76
 • Operate water treatment and disposal systems
so that they do not become a source of contamination.
If grounds not under your control border the plant,
protect your facility by inspection, extermination, or
other means to exclude pests, dirt, and filth that may
be a source of food contamination.
Monitor and maintain facilities regularly
Regularly inspect all facilities to check for evidence
of pest populations or animal contamination. Minimize
the availability of food and water to pests. ·
Remove dead or trapped birds, insects, rodents,
and other pests promptly to ensure clean and sanitary
facilities and to avoid attracting additional pests.
Ensure that potential nesting or hiding places for
pests have been eliminated. ·
If the plant was fogged with insecticide, clean,
sanitize and inspect all equipment afterwards to
insure removal of all dead insects.
Follow all applicable label directions, including
proper disposal of empty containers.

77
 REFERENCES

1. Codex Recommended code of practice 1 - 1969 -

rev 2003.
2. Brockmann So; Piechotowski I; Kimmig P: Salmonella
in sesame seed. J Food Prot. 2004 Jan;67(1):178-80.
3. Emrah Torlak , Durmuş Sert ,Pınar Serin; Fate of
Salmonella during sesame seeds roasting and storage
of Tahina International Journal of Food Microbiology
2013 | 163 | 2-3 | 214-217 .
4. FDA (Food and Drug Administration), 2009a.
Guidance for Industry: Measures to Address the Risk for
Contamination by Salmonella Species in Food Containing
a Pistachio-Derived Product as an Ingredient; Draft
Guidance dated June 2009.
5. GMA (Grocery Manufacturers Association), 2009a.
Control of Salmonella in Low Moisture Foods.
6. LIBNOR standards 71/2002 for Tahina.
7. LIBNOR standard 230/2001 for halawa Tahinaeh.
8. Liu, T. S., G. H. Snoeyenbos, and V. L. Carlson. 1969.
Thermal resistance of Salmonella senftenberg 775W in
dry animal feeds. Avian Diseases 13:611-631.
9. WHO HACCP for the Eastern Mediterranean
R e gi o n .

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