production - hdc

WORLD HALAL RESEARCH SUMMIT 2010
23 RD – 25 TH June 2010
Kuala Lumpur Convention Centre (KLCC)
Dr. Mohamed Shafit Hussain
Food Technology Research Centre
Malaysian Agricultural Research And Development Institute (MARDI)

PRESENTATION OUTLINE
• Introduction
• Focusing R&D for halal food industry
• MARDI’s services to halal food industry
• Commercialization of R&D technologies
• Summary

HALAL SCIENCE
• Issues pertaining to ‘halalness’
• Financial,
• Banking system,
• Processing system,
• Monitoring system,
• Transportation and distribution
• Quality and safety
• Research and development

Research & Development
in Halal Food Industry :
1. Halalan
examples :
2. Thoyyiban
examples :
• Slaughtering
• Food analysis
- e.g. raw materials,
ingredients, additives, GMF.
• Food safety and quality
• Processing equipment
• Packaging/storage
• Distribution/transportation

R&D Centre plays an important role in :
• determining ‘halalness’
• generating new knowledge
• new product development
• improve existing products
• produce quality and safe products
• helping business to grow

Increased food safety
concerns by the customers.
Examples :
• Nipah Virus
• Melamine crisis
• Avian Influenza (AI)
• Bovine spongiform encephalopathy (BSE)
• Severe acute respiratory syndrome (SARS)

Consumer food safety concerns
include the following
1. Chemical residues
2. Antibiotics
3. Hormones
4. Food irradiation
5. Additives
6. Poor sanitation
7. Microbial contamination
8. Pesticides
CHEMICAL
IRRADIATION
FREEZING

Problems with food safety can influence trade flows.
e.g. China’s setbacks for some export products.
Calvin, L., Hu, D., Gale, F. and Lohmar, B. 2006. Food safety improvements underway in
China. Amber Waves, 4(5):16-21.

Challenges to Food Safety: GMOs/GMFs
Another issue of major
relevance in the food
sector is the use of
genetically modified
organisms (GMOs) to
produce genetically
modified foods (GMFs).

GM CROPS
1. Soybean
2. Maize
3. Canola
4. Papaya
5. Sugarbeet
Coming soon :
1. Eggplant
2. Rice
3. Wheat
4. Sugarcane

Science-based guidance
on safe food practices is
vital at all levels – from
farm to consumer – to
prevent contamination of
food during
‣ production
‣ processing
‣ preparation
‣ distribution

Example : Poultry
Test Kit
FROM FARM
CUSTOMERS
TABLE
FORK

RAPID DETECTION KIT FOR PESTICIDE
RESIDUES, ANTIBIOTICS IN POULTRY
AND GMO PRODUCTS.
• Able to detect in a shorter
period of time.

Today’s consumers top trends :-
1. Convenience
• Ready-to-eat/heat
• Custom quick food (e.g. ready
meals, with own personal touch
• Portability to meet the need
‘eat-where-you-are’ such as at
your work desk
• Snacks and mini meals such as
breakfast bars, and wraps

2. Health and wellness
Challenges to Food Safety
• low carbohydrate foods
• nutritious foods
• non-allergic foods
• trans fat free / saturated fats
• weight loss products to combat
obesity

3. Pleasure
Consumers are spending for products that make
their lives easier or provide pleasure.
• comfort foods such as tasty snacks
• gourmet products
• regional cuisine i.e. consumers are
interested in high flavour foods
• ethnic foods

4. Value
The nature of the consumer diet is
changing.
• fresh foods are considered as
better taste, healthier and more
nutritious.
• energy foods e.g. sport drinks,
energy bars and snacks.

Current consumer trends towards :
1. natural
2. minimally processed
3. organically grown foods
- no synthetic pesticides, herbicides, fertilisers,
fungicides, veterinary drugs (e.g. antibiotics,
growth hormones), synthetic preservatives
and additives, irradiation and GMOs.
To consumers it means healthier.

Minimally Processed : Fruits And Vegetables
Fresh-cut: Fresh produce, peeled,
sliced, packed and ready-to-eat or use.
‣ growing due to consumers demand
‣ due to health consciousness
‣ convenient to use
Food Safety Issue : Bacterial growth
‣ preservation techniques such as chlorine and
modified atmosphere packaging (MAP)
‣ A challenge – to reduce pathogen population
‣ Hurdle technology required

FRESH-CUT TECHNOLOGY
OF SUGARCANE FOR EXPORT
MARKET
Maintain quality
Ensure safety
Extend shelf life to
>4 weeks at 5 C
Fresh juice meet the
international food
quality and safety
standards

Examples :
• Colours
• Flavours

GAS EXTRACTION :
• use gas instead of alcohol
• applicable for food flavours and natural oils
• safe, environmentally friendly process
Only one step for the complete process !
Tecnolab
Timatic

Cochineal from insect that grow on nopal cactus di
Mexico, Peru, Chile and Canary Islands.

RED FERMENTED RICE AS
FOOD COLORANT
• The natural colorant was
obtained through
biodegradation of broken rice
using the fungus, Monascus
purpureus on solid state
fermentation.

STARTER CULTURE
Cultured foods have been
consumed for thousands of years
and are essential to good health.
They built resistance to infections,
and greatly enhancing digestion.
They are used in various types of
food products such as fermented
vegetables, meat, yoghurt and
many others.

MARDI Culture Collection :
Examples of products :
1. Soy sauce
2. Nata de coco
3. Tapai
4. Tempeh
5. Yoghurt

• Low calorie
• Low fat
• Low salt
• Low cholesterol
• High fibre
• Enriched products
• Restructure meat products
• Meat Cuts
• Fat Content
• Uniform size
• Packaging

RESEARCH ACHIEVEMENTS
• Enriched eggs for health
High content of Vitamin E,
Omega 3 and selenium
Low cholesterol

HIGH FIBRE DRINKS
• High total and soluble
fibre contents
Pink Guava
• Good functional properties
• Good colonic fermentability
• Low caloric content
Pineapple
Mango

Vacuum Fried
Fruits
‣ Improve quality
attributes of fried food
because of the low
temperatures employed
‣ Able to reduce fat
content of fried products
‣ Able to preserve the
colour of the products

Enzymes :
Application of enzymes :-
• improve yield
• speed-up process
• reduce cost of production
• to improve taste, aroma, colour
• improve texture/bind

• From blood fibrinogen and thrombin
• No ‘tumbling’ and cooking
• Does not require salt or phosphate
• Its 100% natural
• But non-halal

MAKE IT HALAL:
TRANSGLUTAMINASE
USING RECOMBINANT
TECHNOLOGY
• Transglutaminase is use to improve the
physical properties of various foods
e.g restructured meat, surimi-based
products.
• Through biotechnology we are able to
produce transglutaminase.

R&D THRUST AREAS
IN HALAL FOOD
• Development of analysis methods
• Development of halal ingredients
• Development of new value added halal
products
• Improvement in the quality and safety
• Enhancing production and increasing
output

Durian Pulp Destoner
• Overcome labour shortage
• Hygienic. Current practice of
manually scraping is
cumbersome and not hygienic
• Capacity to process up to
30kg of paste per hour with
only one operator as
compared to 12 workers, if
manually done

SATAY SKEWING
Capacity : 1,500 satay/hr (2 operator)
Capacity: 6 time faster
Save time
Easy operation
Operator only needs to place meat
into mould
Automatic skewing

SATAY GRILLING
• Does not require skill operator
• More hygienic and consistent quality
• High grilling capacity compared to
manual
• Grilling cost is lower (RM0.011)
compared to manual (RM0.024) per
stick
• Can be put together in a system
comprising of skewing and
packaging machines
• Suitable for franchising concept

KUIH ROS PROCESSING
MACHINE
• Capacity 800 pieces
per hour
• Uniform and
consistent quality
(shape, colour,
thickness,
crunchiness and
less oily)

REMPEYEK PROCESSING MACHINE
• Capacity 700
pieces/hour
• Uniform &
consistent
quality (shape,
color, thickness,
crunchiness &
less oily)

Under Development :
1. Padang Besar Halal Hub, Perlis
2. Sungai Petani Halal Food Park Kedah
3. Perda Halal Food Park Penang
4. Pengkalan Chepa HFP, Kelantan
5. Pasir Mas Halal Food Park, Kelantan
6. Chendering Halal Food Park, Terengganu
7. Gambang Halal Park, Pahang
8. Labuan Halal Distribution Hub WP Labuan
9. Tanjung Manis Halal Hub, Sarawak
In Operation :
1. Selangor Halal Hub
2. Port Klang Free Zone
3. Pedas Halal Park
4. Serkam Halal Food Park
HALAL FOOD HUB

COMMON SERVICES:
• Cold room for raw materials
• Cold room for finished products
• Storage for ingredients
• Storage for packaging materials
• Waste water/effluent treatment
Centralized Food Park would
greatly facilitate the implementation
of an effective traceability system.

ALONG THE FOOD CHAIN: TRACEABILITY
The key to traceability is
the application of a unique
identification system
applied along the food
chain.
INPUTS PRODUCER PROCESSOR DISTRIBUTOR WHOLESALER RETAILER

Beef traceability
‣ Turmoil after the BSE outbreak
‣ Decrease of beef consumption
Individual Identification
Number10 digits
1 5
Abattoirs Sellers Consumers
Enforcement of the Law :
December 1 st 2004

1. R&D CONTRACT RESEARCH
Contract and collaborative research
(Food science, food safety, product
development, processing,
packaging, post harvest handling)
2. KNOWLEDGE AND SKILL
DEVELOPMENT
Publications, Training, S&T
Exhibitions
3. TECHNICAL ADVISORY
SERVICES
Laboratory Analysis, Trouble
Shooting, Technology Clinics

4. ENTREPRENEURIAL DEVELOPMENT
Quality Improvement, Technology Testbed,
Product Diversification, Adoption
Scheme
5. TECHNOLOGY DEVELOPMENT
Production & Processing System,
Planting Material, Seeds & Livestock
Breeds, QAS, Contract R&D
6. BUSINESS DEVELOPMENT
Consultancy, Technology Incubators,
Technology Licensing, Joint Ventures,
Business Forums

R&D
CENTRE
Technical Expertise
-Product development
-Economic analysis
-Food Regulation
-GMP
-SOP
-HACCP
-MQAS
-HALAL
TEST-BED
INCUBATOR
CENTRE
ENTREPRENEURS

Test Bed Systems
‣ Serdang – sauces, beverages,
bakery product and pasta
‣ Johor Bahru – beverages,
sauces, snacks, jams and fruits
spread
‣ Cameron Highlands, Pahang –
jam and spreads, beverages
‣ Bukit Raya – traditional rice
snacks
‣ Manir, Kuala Terengganu –
fishery products
‣ Besut, Terengganu – frozen
food products

Test Bed Systems
‣ Pasir Putih, Kelantan – drinks,
sauces, pickles and traditional cakes
‣ Kuching, Sarawak – convenient food,
drink, bakery products and fish products
‣ Kota Kinabalu, Sabah – Bakery
products, fishery products, drinks, fruits
snacks and traditional cakes

Technology Incubator Systems
4 technology incubators established:
‣ Stesen MARDI Alor Star –
extruded rice based snacks
‣ Stesen Bukit Tangga – fruit
based products
‣ Stesen Kuala Linggi – essential
oils from herbs and spices
‣ Serdang – animal feed based on
oil palm fronds
Stesen Alor Star
Stesen Linggi

MARDI TECHNOLOGY COMMERCIALISATION
Tacara Sdn. Bhd
- Semi refined carrageenan
Centrifugal Process Sdn. Bhd.
- Fruit Juice, Puree
Mentari Corporation Sdn. Bhd.
- Pastry based products
YBH Products Sdn. Bhd. -
Fruit Juice, Fruit Cordial
Nada Food Sdn. Bhd. - Noodle,
Kuey Teow
Sal’s Food Industries Sdn.
Bhd. - Retort Pouch Products

MARDITECH
CORPORATION SDN BHD
(241148-A)
OBJECTIVE
TO MARKET MARDI’S
INTELLECTUAL CAPITAL
TO PROVIDE A PLATFORM
FOR INTEGRATING R&D
RESULTS AND INDUSTRY
NEEDS
TO DEVELOP CAPACITY AS
AN INTEGRATOR FOR
TECHNOLOGY INNOVATION
INITIATIVES
DEVELOP VIABLE
TECHNOLOGY-BASED
BUSINESS OPPORTUNITIES
Malaysian Agricultural Research & Development Institute

Summary
R&D will continue to be important for the
halal food industry. Through R&D new
halal products are developed, quality
and safe products are produced
and helping
business to grow
especially in halal
food products.

Further Information :
Director General
Malaysian Agricultural Research And Development Institute
GPO Box 12301
50774 Kuala Lumpur
MALAYSIA
Website: www.mardi.gov.my