PREAMBLE - Professor Jayashankar Telangana State ... · accreditation with NABL and implements ISO/IEC 17025:2005 Quality Management Systems. The paradigm shift in Indian agriculture

PREAMBLE The MFPI – Quality Control Laboratory is an advanced, accredited research facility of the University

delivering end to end food testing solutions of raw and processed food commodities. The lab takes up research

studies in determining various nutritional, bio-active, functional and anti nutritional composition in a wide

spectrum of food matrices existing in food value chain, using standard test protocols and high end equipment

maintained in state of calibration with internationally traceable Certified Reference Material. The lab is under

accreditation with NABL and implements ISO/IEC 17025:2005 Quality Management Systems.

The paradigm shift in Indian agriculture witnessed in case of food commodities from quantity to quality

is a welcome phenomenon in the context of present World order. With a total food grain production of 250 mt,

32 m MT of fruits and 71 m MT of vegetables India has established itself as food secured nation. The rapid

growth in allied sectors like diary, poultry and fisheries has further consolidated India's position as a nation with

marketable surplus. Consequently, our country has transitioned from production economy to market economy

encompassing growth, productivity, diversity, profitability and quality assurance. This transformation has led to

a spurt in processing activities of food commodities at various levels leading to free availability of processed

food at affordable cost. The pivotal role of “Testing Laboratories” in ensuring high quality standards of food

material has become much more relevant than before.

"Food safety" implies absence or acceptable and safe levels of contaminants, adulterants, naturally

occurring toxins or any other substance that may make food injurious to health on an acute or chronic basis.

Food quality can be considered as a complex characteristic of food that determines its value or acceptability to

consumers.

Food Quality Assurance is accomplished with the implementation of GAP, GMP, GHP, HACCP, MRA,

QM, ISO 9000 series (9000-9004) and 14000 and TQM. GMP covers the fundamental principles, procedures

and means needed to design an environment suitable for the production of acceptable quality. GHP describes the

basic hygienic measures that establishments should meet and which are the perquisites to other approaches, in

particular HACCP. GMP/GHP requirements have been developed by governments, codex and food industry in

collaboration with other groups, food inspection and control authorities.

In this context, main objective of the enforcement of quality assurance is to improve capabilities of a country

to enforce food safety norms according to Codex standards including food additives, food contaminants and heavy

metals, methods of analysis, sampling methods, import and export inspection and certification systems, residues of

veterinary drugs, pesticide residues, microbiological hazards, labeling, codes of practices, allergens, novel foods and

GMO's and product composition.

In India the “Food Safety and Standards Act of 2006” (FSSAI) came into force across the country on August

5, 2011, making it at par with the international standards. The act is enforced to ensure improved quality of food for

the consumers and censure misleading claims and advertisement by those in food business. FSSAI, established under

the overarching legislation, will lay down science based standards for food items and regulate their manufacture,

storage, distribution, sale and import to ensure availability of safe and wholesome food for human consumption.

Implementation and enforcement includes the areas like managing pesticide residue, traceability, testing facilities,

promote or penalise, penalty provisions, consumer safeguards, safeguards for food businesses and labelling.

To accomplish the task of Food quality control as per the provisions under FSSAI, an analytical

capacity is the basic requirement to monitor the safety of food. An efficient lab facility engaged in food quality

analysis needs to integrate analytical capability for microbiological safety of food, toxicity of chemicals in

foods, novel foods and processes, pesticides and veterinary residues.

MFPI-QUALITY CONTROL LABORATORY, PJTSAU, RAJENDRA NAGAR,

HYDERABAD

The Genesis

In pursuance with the vision for establishment of efficient Food Quality Control System, PJTSAU had

prioritized setting up of state-of-art, accredited Quality Control Facility to assist institutions and

entrepreneurs in fulfilling the requirements for implementation of international standards by analysis

of food samples, providing quality assurance services and technology transfer. Through an MOU

with the Ministry of Food Processing Industries, Government of India, the University in the year

2007-08 has established a well equipped Laboratory with high end analytical instruments run on

internationally accepted protocols. Essential infrastructural facilities include well furnished testing

lab rooms, a dedicated power line, soft water supply line, uninterrupted power supply to support all

the equipment, enclosure for gas cylinders and fire fighting equipment.

Objectives

• To comply with QCI/NABL Accreditation requirements in the field of nutritional profiling of

farm produce and processed foods for stakeholders involved in food chain.

• To generate quality data base for the most important genetic material developed in various crop

improvement programmes by the University and their processed products by highlighting

inherent superiority in terms of value addition.

• To apply Radiation Technology to create heritable variation in crops and to enhance shelf life

of agricultural produce.

• To explore the functional and nutraceutical properties in commonly consumed and

underutilized foods for enhancing food and nutritional security to address malnutrition.

• To screen for superior naturally fortified genotypes which can serve as staple source of

essential micronutrients in value chain.

• To provide consultancy services in food testing and analysis for various food matrices in the

value chain.

Deliverables:

• Nutritional profiling of raw and processed food matrices under NABL Certification for all

stakeholders.

• Profiling of raw and processed foods for amino acids, fatty acids, elements and proximates for

providing critical inputs to the crop improvement schemes of the University.

• Development of protocols for estimation of important nutritional and anti nutritional

components in various foods and variants for trait based plant types.

• Screening commonly consumed and underutilized foods for antioxidants, phenolics,

flavonoids, carotenoids, lupeol etc.

• Estimating the retention of essential micronutrients like iron and zinc in most important staple

food crop - rice in respect of post harvest processing.

• Creating “Centre of Excellence” facility for conducting academic research and meeting the

commercial analytical needs.

Beneficiaries of deliverables:

University researchers, farmers, food processing sector, various national and international agricultural

research institutes (ICRISAT, ICAR, SAU’s, IICT etc) and consumers.

Quality Assurance Policy of the Lab

The MFPI-Quality Control Lab at Professor Jayashankar Telangana State Agricultural University is

committed to the standards of ethical conduct which define the obligations of public service. The QC lab

also has the responsibility of satisfying all the stake holders and be conscious of its environmental

responsibilities. The laboratory management and personnel are oriented towards performing quality

activities to assure integrity, accuracy, precision, reliability and timeliness of the data to be in the

service of farmers and the society at large. The laboratory's standard of service for the testing

programme is well defined and towards this objective, we will train our human resources on a

continual basis and keep them motivated to give optimum performance.

Implementation of ISO:17025 standards in the Lab

General requirements for the competence to carry out tests and/or calibrations as per

international standards specified under ISO/IEC 17025:2005(E) are complied with, in carrying out all

the pre analysis and analytical protocols of the Lab.

The issues covered under clause-4 (Management requirements) include Organisation(4.1),

Management system(4.2), Document control(4.3), Review of requests, tenders and contracts (4.4),

Subcontracting of tests and calibrations(4.5), Purchasing services and supplies(4.6), Service to the

consumer(4.8), Control of nonconforming testing and/or calibration work(4.9), Improvement(4.10),

Corrective action(4.11), Preventive action(4.12), Control of records(4.13), Internal audits(4.14), and

Management reviews(4.15).

The clause 5 (Technical requirements) covers issues like General(5.1), Personnel(5.2),

Accommodation and environmental conditions(5.3), Test and calibration methods and method

validation(5.4), Equipment(5.5), Measurement traceability(5.6), Sampling(5.7), Handling of test and

calibration items(5.8), Assuring the quality of test and calibration results(5.9) and Reporting the

results(5.10).

NABL Accreditation – MFPI Quality Control Laboratory: MFPI Quality Control

laboratory has got the prestigious NABL (National Accreditation Board for Testing and Calibration

Laboratories) Accreditation during 2015, for Chemical testing services providing an array of analytical

services in raw food grains and their processed products. QC lab has now upgraded the Quality

Management System with internationally accepted standards and guidelines i.e., ISO/IEC 17025:2005.

The lab provides analytical services at affordable rates for farmers, small scale entrepreneurs, research

organizations and research scholars on commercial basis. The lab has developed expertise in rendering

services of high standards and traceability with respect to nutritional profiling, vitamin estimation,

fatty acid and amino acid profiling, micronutrient and heavy metal analysis and microbiological testing

for fungal and bacterial organisms.

Performance results:

The present Quality Management System includes documentation pertaining

to the following quality control activities:

1. Equipment maintenance, calibrations, AMCs, intermediate checking

and trouble shooting.

2. Proficiency testing and inter-laboratory testing for proximate analysis

3. Training of Staff on quality and managerial aspects of ISO/IEC-

17025/2005, as well as equipment usage and handling of SOPs

4. Organization and personnel records

5. Document control to establish high degree of traceability

6. Continuous improvement through customer feedback and handling of

customer complaints

7. Utilization of NIST traceable reference standards for error free results

8. Adoption of stringent internal quality control mechanism for accurate

results

9. Quality plan, retesting and repeat testing for competence of testing

capability of staff

10. Maintenance of records pertaining to uncertainty measurements as a testimony of precision of

the results issued by the laboratory. NABL accreditation certificate

Impact & benefits:

Availability of an accredited laboratory working on the principles of ISO/IEC 17025:2005 quality

management system provides strong science based approach towards food related research. This will

enhance the credibility of the University in terms of data base generation and its utilization with regard

to crop genetic resources developed by the university and also add value to the processed products

designed out of those varieties through the efforts of food scientists of the laboratory. Such accredited

facility will help the stake holders of food chain in meeting the labeling requirements of FSSAI.

Location

The lab is situated on the Himayat Sagar main road in the Extension Education Institute campus of

PJTSAU, Rajendranagar, Hyderabad - 500 030.

Provisions :

The total operational area of the lab : 6000 s ft

Sample Reception Area

Information Display Area Wet Lab

Clean Rooms for Microbiology Testing Air Handling Unit

Molecular Testing Lab Cold Chambers

Chemical Storage Area Instrumentation Lab-I

Record Rooms Power Distribution Room

UPS Rooms Wash Rooms with First Aid Facilities

Staff members:

S.No Designation Numbers of persons

1. Principal Scientist 1

2. Sr. Scientist 1

3 Research Associates 2

4. Technical Assistants 4

5. Computer Operator 1

6. Lab Attender 1

7. Security guards 1

ANALYTICAL CAPABILITY

I. Elemental estimation Scope Natural processes and contamination influence elemental levels in food material. Elements with

potential health hazards are Mercury (Hg), Palladium (Pd), Chromium, (Cr), Manganese (Mn),

Cobalt (Co), Nickel (Ni), Arsenic (As), and Cadmium (Cd) etc., Rapid industrialization and metal

prospecting has increased the levels of toxic metals in aquatic and soil ecosystem. Heavy metals

being immobile get accumulated in soil and food material. Such accumulation leads to the entry of

metals into food chain. On the other hand mineral profiling of food substances indicates the

nutritional worth and presence of essential elements which play a vital role in metabolism.

Estimation of trace elements upto ppb levels enhances the validity of the data generated in this

regard.

Execution

Inductively Coupled Plasma Optical Emission Spectrometer(ICP)

· Model : Prodigy XP

· Make : M/s Teledyne Leeman labs

Technique

· Simultaneous estimation of minerals from samples with high dissolved solids(25%) · CCD detector with EChelle grating, Polychromator · High through put with cyclonic spray chamber

· Dual view optics : (1) Axial (2) Radial

· Wave length range : 165nm to 1100nm

Gases used

Nitrogen, Argon

Sample range

Cereals, vegetables, pulses, fruits, processed food items and agricultural resources.

Clientale

Department of Agriculture, Agricultural research stations of PJTSAU, ICAR research

institutes like DSR, DRR, CRIDA, Private food industries, Farmers, Research Scholars, Food

and Pharma industry.

II. NUTRITIONAL PROFILING

Scope

With the promulgation of Food Safety and Standards Act 2006, labelling has become a vital

link in the food industry. Estimation of proximates viz., moisture, protein, carbohydrates,

fat, fibre, ash, vitamins etc., is of immense practical utility in creating awareness among all

stake holders involved in food sector. Automatic analysers for nutritional profiling are

universally accepted and deliver valid data which is consistent and reliable with high degree

of precision.

Execution

Automatic Protein Analyser

· Model : FP-528

· Make : M/s Leco instruments

Technique

Initially the amino nitrogen content in the sample is converted into total organic nitrogen

by combustion of the sample. The nitrogen content thus obtained is multiplied with 6.25 to get

protein content of the sample.

Gases used

Helium, Oxygen

Sample range

Cereals, Pulses & their Products leafy vegetables, vegetables, herbal preparation,

cooked products etc., Soxtherm Fat Analyser

· Model : 1029

· Make : Gerhardt

Technique

Estimates fat/oil content in the sample. The sample is extracted with petroleum ether. After

extraction for 1 hr. 36 min. the difference in the weights gives the fat content. Handles four

samples at once. Sample range

Cereals, Pulses & their products, leafy vegetables, herbal preparations etc., Fibertherm Crude Fibre Analyser

· Model : FT12

· Make : Gerhardt

Technique

Estimates crude fibre content in the sample. At a time digests 12 samples. Moisture and fat free

sample is digested for 1 hr. 46 min. and kept in the hot air oven and muffle furnace. The difference in

the crucible weight gives the weight of the fibre content in the sample per 100g. Sample range

Cereals, Pulses & their products, leaf vegetable, vegetables, herbal preparations, cooked products etc., III VITAMIN AND AMINO ACID PROFILING

· Model : Polar10B00

· Make : M/s Varian

Technique

· Pumps : Quaternary pump module

· Column : C-18 Reverse phase column

· Mobile phase : Hexane sulfonic acid Na salt, Methanol, Aceto nitrile and

Chloroform

· Detector : UV –Vis detector, RI Detector, Fluorescence Detector

· Light sources : Deuterium lamp for UV and Quartz halogen for Vis

Estimates Amino Acid composition and B complex vitamins(thiamin, riboflavin, pyridoxine, niacin,

Nicotinamide, Folic acid) fat soluble vitamins (Vitamin A and B carotene), gossypol and isoflavones,

etc., using NIST traceable standards at one run for 20- 30 min. Samples are extracted with suitable

solvents and injected into HPLC. Quantification is done based on the standard retention time and

peak area. Sample range

Cereals, pulses and their products.

· Model : 1260 Infinity

· Make : M/s Agilent

UV-VIS Spectrophotometer

· Model : CE 7200

· Make : CECIL

Technique

Dual silicon photodiode

WL Range : 190-900 nm

WL calibration : Automatic at switch on

Works on the principle of light absorbance. Standards are prepared at different concentrations

and the colour is developed with different intensities. Standard graph is prepared based on the

absorbance. Once the samples are processed the concentration of the sample for the particular

parameter is read in the standard graph. Estimates sugars, carbohydrates, phytates , tannins,

total and B carotene and protein at different wavelengths.

Sample range

Cereals, Pulses, leafy vegetables, other vegetables and their products.

Clientale

Agricultural research stations of PJTSAU, ICAR institutes like DSR, DRR, CRIDA, APEDA,

Private food industries, Farmers, Research Scholars, AP Foods and Pharma industry.

III. FATTY ACID PROFILING

Scope

Edible oil consumption constitutes major portion of dietary intake by average Indians. A

wide variety of refined sources of edible oils are available in modern society. These sources from

different oil seed crops vary in the constitution of fatty acids making them specific for this

purpose. Though unsaturated fatty acids are recommended for good health, excess unsaturation

also results in poor keeping quality of oils. Hence, it is very essential to have a balance between

saturated and unsaturated fats to avail benefits of good health and consumer quality. In this

connection, profiling of major fatty acids available in oil seed crop varieties released by PJTSAU

is essential so as to prepare a data base for use by the Breeders and others concerned for

developing elite varieties in future, and also identify any unusual changes in composition which

might have beneficial/detrimental effects on health.

Execution

Equipment

Gas chromatography

· Model : Clarus 500GC

· Make : M/s Perkin elmer

Technique

Detectors

· FID ( Flame Ionization Detector)

· NPD (Nitrogen phosphorus Detector to detect Organophosphate pesticides) · ECD (Electron capture detector to detect Organochlorine and Carbamate pesticides)

· Solvents : Acetone, Acetonitrile, Dichloromethane and Hexane.

· Capillary Column (5% Diphenyl, 95% Dimethyl polysiloxane)

· Carrier gas : Nitrogen

· Equipped with Autosampler

Standards available : Acephate, Carbofuran, Chlorpyriphos, Chlorpyriphos-methyl, Dimethoate, Endosulfan, Malathion, Monocrotophos, Quinolphos.

· Model : 7890B

· Make : M/s Agilent

Sample is extracted with suitable solvents and then injected into GC using FAME procedure. Sample

gets vapourized and migrates along with the mobile phase i.e, carrier gas and is then detected.

Pesticide in a sample is quantified by plotting against standard retention time and peak area. Gases used:

Nitrogen, Hydrogen and Dry air. V. MICROBIAL TESTING

Scope

Presence of harmful microbial organisms in food stuffs is a major emerging challenge

worldwide, to comply with Food Safety regulations. Toxins released by microbes are potentially

hazardous. Testing of food samples for the presence of bacteria, fungi etc., warrants establishing

lab infrastructure with international standards.

Technique

Clean rooms with modular wall panels and non walkable ceiling panels supported by

recirculation Air Handling Units comprising of Heating Ventilation Air Conditioning system

(HVAC) and High Efficiency Particulate Air filters (HEPA) of 99.997% down to 0.3 micron rating

are under operation. The entire clean room area of approximately 600 sft comprises of three

change rooms, sample preparation/ instrumentation room, clean corridor, three clean rooms and

a critical area housing the Laminar air flow. The entire facility is validated for parameters like air

balancing, room pressure adjustments, temperature and relative humidity adjustments, terminal

HEPA installation leakage test, clean room classification test and documentation of validation

and testing results as per ISO-7 and ISO-8 standards.

Equipment

Laminar Air Flow Chamber (LAF)

· Make : Smart lab tech Pvt.lt

Used for sample inoculation and serial dilution, sub culturing, culture inoculation. LAF bench is

kept in restricted area to maintain the sterile condition.

Provisions

· HEPA FILTERS : To check the performance of Air Quality system

· MAGNAHELIC GUAGE : To check the pressure flow inside the chamber using Valometer

(12 to 18mm)

· FLAME : Glass beads or electric burner.

· PASS BOXES : To pass the autoclave material to LAF bench.

· HYGROMETER : To check the room humidity

Sample range

Cereals, flours, fruit juices, beverages, rural and urban cooked and raw food items, organically

developed antifungal agents, medicinal plant leaf powders, water samples.

Clientale

Food and beverage industries, UNICEF projects, Research scholars, Faculty of Home Science.

VI. RADIATION PROCESSING OF SEED AND FOOD

Gamma Chamber 5000 is a category I gamma irradiator providing an irradiation volume of

approximately 5000cc. The material for irradiation is placed in a irradiation chamber located in

vertical drawer inside the Lead flask. This drawer can be moved up and down with the help of a

system of motorized drive, which enables precise positioning of the irradiation chamber at the center of

the irradiation field. Radiation field is provided by a set of stationary Cobalt-60 source placed in a

cylindrical cage. The source is doubly encapsulated in corrosion resistant stainless steel pencils and

was tested in accordance with international standards. Two access holes of 8 mm diameter are

provided of service sleeves for gasses, thermocouple, etc. Mechanism for rotating/ stirring samples

during irradiation is also incorporated. The Lead shield provided around the source is adequate to keep

the external radiation field well within permissible limits. The quantity absorbed dose (kGy) can be

defined as the amount of energy absorbed per unit mass of the matter at the point of interest.

Application:

Radiation processing of Seed, raw grain and processed food commodities can be irradiated by exposing

to Gamma radiation at desired dose rate. This could be applied for purposes like enhancing shelf life, to

induce point mutations, surface disinfestations and disinfection, to maintain seed viability of field crops

etc.,

SAMPLES ANALYZED SO FAR: (2007-2018)

PARAMETERS No. of SAMPLES

Heavy metals 14778

Toxins 10

Pesticide residues 648

Microbiology 1951

Irradiation 1490

General Quality 4900

Vitamins 1650

Proximates 8228

TOTAL: 33,655

Scope of Analysis

(Name of analytes & matrix)

Testing fee (in Rupees) per sample

Other organizations /

agencies

PJTSAU Farming

community

(limited to few

samples) Commercial

testing

Research

purposes

Research schemes /

colleges

1. Foods & Agricultural

products

Industry /

institute

Other

students

PJTSAU PJTSAU

Students

Farmers

Bench Fee 20,000 / 3 months

Minerals & Heavy Metals

Up to 3 Heavy Metals Per Sample 1575 1250 1250 850 1060

Up to 3 Minerals Per Sample 1575 1250 1250 850 1060

Vitamins

Ascorbic acid 1190 900 900 375 695

Thiamine 1375 1015 1015 425 800

Riboflavin 1375 1015 1015 425 800

Niacin 1375 1015 1015 425 800

Total Carotenoids 1375 1015 1015 425 800

Beta Carotenes 1375 1015 1015 425 800

Lycopene 1375 1015 1015 425 800

Sugars

Total Sugars 940 750 750 375 500

Reducing sugars 940 750 750 375 500

Acidity 350 170 170 100 125

TSS 250 190 190 125 150

Sugar : Acid Ratio 350 170 170 100 125

Pulp : Stone Ratio (For fruits) 350 170 170 100 125

Proximates

Moisture 200 190 190 165 165

Ash 270 250 250 215 215

Total Protein 850 750 750 425 500

Total fat 850 620 620 425 500

Crude Fibre 850 625 625 425 500

Carbohydrates 1050 750 750 530 590

Nutritional Profiling

Fatty acid profile 2500 2250 2250 1900 1500

Amino acid profile 2500 2250 2250 1900 1500

Total Aox Activity 1700 1240 1240 700 850

Total Phenols 1700 1240 1240 700 850

Total Flavonoids 1700 1240 1240 700 850

Total Chlorophyll 800 565 565 320 530

Anti nutritional Factors

Phytates 2000 1350 1350 900 1070

Tannins 2000 1350 1350 900 1070

Oxalates 2000 1350 1350 900 1070

Saponins 2000 1350 1350 900 1070

Organoleptic & Cooking quality evaluation

Sensory Evaluation 400 340 340 220 300

Alkali spread Value 200 190 190 165 165

Gelatinization Temperature 200 190 190 165 165

Cooking Quality (Cereal/Pulses) 400 380 380 320 320

Gluten 340 230 230 125 170

Grain Quality Parameters

Length, Breadth, L/B ratio, Area 340 230 230 125 220

Hulling Recovery (per 100gm) 70 65 65 65 65

Milling Recovery (per 100gm) 65 65 65 65 65

Microbiology

TBC 1600 1250 1250 970 1060

TMC 1600 1250 1250 970 1060

Radiation Processing

0.1to 0.5 kGy 400 280 280 160 200

>0.5 to 1.0 kGy 500 350 350 200 250

>1.0 to 1.5 kGy 600 420 420 240 300

> 1.5 to 2.0 kGy 700 490 490 280 350

>2.0 to 5.0 kGy 1300 910 910 520 650

>5.0 to 10.0 kGy 1500 1050 1050 600 750

Use of Equipments (Per Hour)

Colourflex 525 400 400 270 320

Autoclave 200 190 190 165 165

Refrigerated Centrifuge 35 30 30 30 30

Microscope with camera 140 125 125 125 125

Bacteriological Incubator 270 250 250 220 220

UV-Vis Spectrophotometer 75 65 65 65 65

Laminar Airflow (Inoculation) 200 190 190 165 165

Other Accessory Equipments 265 250 250 220 220

Cold Chambers (Per Day) 500 500 500 350 300

Address:

Principal Scientist & Head,

MFPI-Quality Control Laboratory, Professor Jayashankar Telangana State Agricultural University,

Rajendranagar, Hyderabad-500 030,

Telangana State, India.

Ph: 040-24013456, Cell: 9949437035

E-mail: [email protected]