11 Aug How to make and store pre-cooked pulses to guarantee food safety

Posted at 00:00h in Food, Pulses by

Just like any other food, pre-cooked pulses must be safe. To ensure this is the case, following best practices in all phases of the creation process is crucial: from production at the factory to handling in retail and/or food service outlets. All of them face the constant challenge of guaranteeing the safety and quality of the foods they offer.

This is also true with pre-cooked pulses, which require special attention in each phase of preparation. Making sure these products reach consumers in optimal conditions not only protects their health, but also strengthens the reputation of the companies and establishments involved.

GOOD MANUFACTURING PRACTICES

Receipt of the raw material

Food safety begins from the time the raw pulses are received in the factory. Several actions must be taken in this first phase:

  1. Inspection and quality: Visually inspecting the pulses is essential to detecting possible contaminants, such as stones, soil and insects. Plus, quality testing must be done to ensure the pulses comply with the required standards.
  2. Initial storage: Pulses must be stored in the proper conditions, in a fresh, dry location, in order to prevent the proliferation of fungi and bacteria.
  3. Traceability records: Keeping detailed records of the origin of the pulses is crucial to traceability. This helps quickly identify the source if there are any food safety issues.

Cleaning and preparation

Before production, the pulses must go through a cleaning and preparation process:

  1. Washing: Pulses must be carefully washed to eliminate any dust, soil or pesticide remains. This can be done with industrial washing equipment.
  2. Selection and sorting: After washing, pulses must be sorted to eliminate any that are damaged or in poor conditions. This guarantees only high-quality products reach the cooking process.

Cooking

Cooking pulses is a critical phase when it comes to ensuring their safety and, above all, offering the highest nutritional quality:

  1. Temperature control: Cooking pulses at the right temperature to eliminate any potential pathogen is crucial. The minimum recommended temperature is 90ºC for at least 10 minutes.
  2. Continuous monitoring: The temperature and time must be constantly monitored throughout cooking to ensure all batches are cooked evenly.
  3. Quick cooling: After cooking, the pulses must be quickly cooled to prevent the growth of bacteria. Cooling is done using industrial cooling systems to ensure a quick drop in temperature.

Packaging and labelling

Packaging and labelling are the final steps in the process before the pre-cooked pulses reach consumers:

  1. Sterile packaging: Using sterile, air-tight packaging is necessary to prevent contamination after cooking. The packaging must be made of the right material for food preservation, such as glass jars or tins.
  2. Clear and precise labelling: Labels must provide clear information on the product, including the date of production, date of expiry, ingredients and any allergen that may be present.
  3. Final quality control: Final inspections are necessary to ensure the products comply with all the quality and safety standards before distribution.

BEST STORAGE PRACTICES AT RETAIL AND FOOD SERVICE ESTABLISHMENTS

Retail storage

Keeping pre-cooked pulses in the ideal conditions to maintain their freshness and safety is crucial in retail:

  1. Storage conditions: Pre-cooked pulses can be stored at room temperature, yet always under 25ºC to prevent the risk of bacteria growth.
  2. Inventory rotation: Implementing a FIFO (First In, First Out) system to ensure the oldest products are sold first reduces the risk of selling expired products. Furthermore, this product placement technique also affects sales.
  3. Regular inspections: Conducting regular inspections to verify the products are not damaged and the storage conditions are appropriate.

Food service storage

Following strict handling practices at restaurants is essential to preventing cross-contamination and keeping pre-cooked pulses fresh:

  1. Separate storage: Once removed from their original containers, pre-cooked pulses must be stored separately from other raw foods to prevent cross-contamination.
  2. Hygienic handling: Employees must use gloves and clean utensils when handling pre-cooked pulses. Plus, they must wash their hands frequently.
  3. Safe reheating: When reheating pulses, it’s important to reach an internal temperature of at least 74°C to eliminate any pathogen that may have grown during storage.

TIPS FOR KEEPING PRODUCTS FRESH

To keep the product fresh, attention must be paid to three factors: temperature, air-tightness and the speed of consumption.

  1. Storage temperature: Pre-cooked pulses can be stored at room temperature, yet always under 25ºC., as specified in its technical sheet. However, once open, they must be stored refrigerated in a non-metallic container. A constant and adequate temperature must be maintained to preserve freshness, as temperature changes can accelerate deterioration.
  2. Air-tight sealing: Making sure packaging is well sealed to avoid the entrance of air and contaminants is fundamental, as it helps keep the product fresh and extend its shelf life.
  3. Quick consumption: Pre-cooked pulses can have an expiry date of up to 5 years. However, once open, they must be consumed within three days maximum. This ensures they are eaten at the ideal point of freshness and flavour.

 

Proper preparation, storage and handling of pre-cooked pulses are fundamental to ensuring food safety. From the time the raw material is received at the plant and all the way to handling at retail and food service outlets, each phase in the process must follow strict quality and hygiene standards.

Implementing these best practices not only protects consumers’ health, but also ensures the freshness and nutritional value of the pre-cooked pulses.