article · Journal of Food Safety
Cashew nut processing requires strict controls to prevent microbial contamination and aflatoxin formation. An industrial case study evaluated Hazard Analysis and Critical Control Point measures during processing, identifying drying operations as critical control points. Multi-stage drying successfully lowered moisture content from 8.60 to 3.86 grams per 100 grams. This moisture loss directly reduced yeast and mould counts, whilst preventing detectable aflatoxin formation throughout the entire process. In contrast, total plate counts saw modest reductions, shifting from 3.98 to 2.57 Log CFU/g, which demonstrates microbial persistence even in low-moisture conditions. Furthermore, drying improved lipid stability by reducing free fatty acids and peroxide values. The findings demonstrate that ensuring cashew nut safety and quality depends on a multi-barrier approach that unites thermal moisture control with robust hygienic practices across the production line.
Cashew nuts are valuable nutritional commodities, but microbial contamination and aflatoxins present serious food safety risks. Identifying drying as a critical control point helps processors ensure product safety, prolong shelf life, and maintain quality. Demonstrating that bacteria persist despite moisture reduction highlights the essential need for comprehensive hygiene programmes alongside drying, protecting consumers and preserving the market value of processed nuts.
The findings are applied and tested within an industrial cashew processing setting. Food processors and quality managers can use these validated drying parameters and HACCP guidelines to optimise commercial nut drying lines, prevent aflatoxins, and enhance lipid stability. Because this work directly evaluates an active industrial workflow, the resulting operational controls are near-market and ready for implementation in commercial processing facilities aiming to meet international safety standards.
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ABSTRACT Cashew nuts are highly valued for their nutritional properties but remain susceptible to microbial contamination and aflatoxin formation during processing. This industrial case study evaluated the effectiveness of Hazard Analysis and Critical Control Point (HACCP)‐based control measures in cashew nut processing, with a focus on drying operations as critical control points. A combined approach including process flow analysis and experimental evaluation of physicochemical and microbiological parameters was applied. The results showed that moisture content decreased significantly from 8.60 g/100 g to 3.86 g/100 g during processing, indicating the efficiency of multi‐stage drying. Consequently, this reduction was associated with a decrease in yeasts and molds. However, total plate counts showed limited variation, decreasing from 3.98 to 2.57 Log CFU/g, thus confirming microbial persistence in low moisture conditions. No aflatoxins were detected at any stage, demonstrating effective prevention of fungal growth through moisture control. In addition, free fatty acids and peroxide values decreased, indicating improved lipid stability. These results highlight the key role of drying operations in controlling safety and quality parameters. This industrial case study confirms that effective HACCP implementation relies on a multi‐barrier approach combining moisture control and hygienic practices in low moisture foods.
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DOI: 10.1111/jfs.70094
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