The effect of applying GMP and HACCP to traditional food processing at a semi-commercial kenkey production plant in Ghana

To manage the hazards, aflatoxins and enteric pathogens, associated with the production of an indigenous African fermented maize product, kenkey, HACCP was implemented at a semi-commercial kenkey production plant in Accra. As a prerequisite programme, the facility was upgraded and GMP implemented before HACCP. The effectiveness of GMP and HACCP was assessed by monitoring the environment and kenkey production, as well as the auditing and verification of HACCP. Air sampling and swapping of equipment surfaces revealed a microbiota which was consistent with the fermented product. Monitoring showed that the raw materials, products, processing parameters, etc, conformed to the critical limits within which the safety of the food product would be ensured. This was confirmed by the results of laboratory analysis of raw materials, intermediary and final products. Escherichia coli, Staphylococcus aureus, Enterococcus, Salmonella, Bacillus cereus, and Vibro cholera were not detected in any of the finished products and the level of total aflatoxins in the kenkey samples were between 17.2 and 14.5 μg/kg. Levels of aflatoxins in kenkey samples reported at the plant before implementation of GMP and HACCP were between 64.1 and 196 μg/kg. Application of GMP and HACCP was therefore found to be effective as a quality management system for assuring the safety of kenkey in the traditional processing of maize into kenkey.