Universidade Federal do Pará – Federal University of Pará

Instituto de Tecnologia – Technology Institute

Faculdade de Engenharia de Alimentos – College of Food Engineering

Belém, PA – Brazil

COOKITOS: A value-added cookie from indigenous agricultural raw materials

and agroindustrial products of the Brazilian Amazon to combat child malnutrition

ANDRADE, T.O.; BENTES, A.C.V.; MARTINS, L.M.; JR PENA, E.; FERREIRA, L. P.

EXECUTIVE SUMMARY

Brazil has an indigenous population of approximately 817,000 of which 168,000 only in

the Amazon Region who base their livelihood on family agriculture[1]

. Highly

consumed, the cassava root (Manihot esculenta) is the staple food, although considered

nutritionally poor[2,3]

. In turn, cassava leaves are rich in protein[4]

, and their processing

represents an opportunity to improve the diet as well as to promote local economic

growth by adapting the "casas de farinha" (the traditional cassava root processing

facility of indigenous origin), to also process cassava leaves and other local crops for

the production of value-added products. This work proposes the production of Cookitos,

a 30g cookie, rich in protein, source of fiber and low in sodium, developed from

indigenous raw materials and local agro-industrial products targeted at children (6-12

years) to combat protein deficiency among the low-income population[5]

. Colorful and

fun packing that refer to the Amazon flora and fauna were used to create a regional

identity around the product. This project is economically feasible and meets the

requirements for implementation and distribution of existing family farming

government programs[6,7]

. Also suggested are options to adapt the product formulation

according to raw material availability to other regions of the country and the world,

where cassava is the staple food and consequently show poor protein diets among the

low-income population, such as in Latin America, Africa and Asia[8]

.

INTRODUCTION

The cassava root (Manihot esculenta) is highly produced and consumed, often used as a

staple food for low-income populations around the world (about 500 million)[9]

.

However, it is considered nutritionally poor for being constituted basically from

carbohydrates[2,3]

. In turn, cassava leaves, which are harvested together with roots, are

rich in protein and minerals[4]

, and their processing pose an opportunity for diet

improvement and growth of the local economy through their pulverization and use as a

high-protein ingredient for the fortification of value-added family farming processed

products. Protein deficiency is the leading cause of child malnutrition in subtropical

countries such as Brazil, Africa and Asia, either by cultural factors or the difficulty of

obtaining nutritionally adequate food[5]

. This nutritional deficiency influences the

growth and also the academic performance of children[10]

. Also, low-income children

living in those countries often have their main meal at public schools supported by

governmental programs such as PNAE – The National School Feeding Program in

Brazil[7]

. Thus, we propose the development of Cookitos, a nutritious product made

from raw materials of indigenous agriculture and local agribusinesses intended for

Brazilian children (6-12 years), as an alternative to preventing protein deficiency[4,5]

.

PRODUCT SCIENCE AND TECHNOLOGY

The nutrient content and delicious taste of Cookitos is a result of its unique formulation

utilizing local ingredients from regional agriculture and agroindustries, including

cassava leaves flour and Brazil nuts cake flour (Bertholletia excelsa), with a significant

amount of protein (25, 8 and 47.6%, respectively), having the latter the power to

mitigate a mild leafy flavor, while contributing to the mineral content of the cookie

[11,12]. Passion fruit peel (Passiflora edulis) and peach palm (Bactris gasipaes) flours

were also used - due to their fiber content (70.67% and 5.58% respectively) [13]

; together

with banana (Musa spp.) flour – to enhance sweetness and color of Cookitos, improving

product acceptance among the local population.

Cookitos are thus formulated with 30% wheat flour, 22% unsalted margarine and 15%

sugar due to technological needs for product texture; 15% Brazil-nut cake, 3.5% of

composite flour mix (pupunha, banana and passion fruit bark) and 1% of pulverized

manioc leaves for protein fortification and product market positioning; and,

additionally, 1.5% chemical leavening (sodium bicarbonate, ammonium phosphate) and

5% of water used as technology aid, according to Brazilian regulation[14]

. Figure 1 in

Appendix A shows the detailed processing of raw materials to obtain the flours as well

as the steps for preparing the cookie[15]

, which must follow good manufacturing

practices established by Brazilian Regulations[16]

.

The safety and quality of Cookitos is based on the low water activity of the final

product measured as being 0,474±0,001 and having a critical limit established at 0,5,

being a processing critical control point (CCP) for biohazards. Microbiological analyzes

performed on the final product indicated the absence of pathogenic and/or the presence

of spoilage microorganisms under permitted values in accordance with the Brazilian

regulation (SP Salmonella, total coliforms, thermotolerant and molds and yeasts)[17]

.

Table 1 (Appendix B) shows in detail all Process Critical Control Points besides aw

measument of final product.

Cassava products may present residual cyanogenic glycosides that pose a risk to human

health in large proportions[18,19]

. However, studies show that processing methods such as

maceration, drying and pulverization, used for production of root flour are effective in

the removal of toxic compounds [20, 21, 22, 23]

. In this context, four varieties of pulverized

manioc leaves made to produce Cookitos were evaluated for cyanide levels found to be

less than 100mg/kg (4-68mg/Kg), the content considered safe for consumption[24]

.

Physicochemical analyzes of the nutritional properties of Cookitos showed that it has

12g/100g of protein, showing it can be declared as protein rich according to Brazilian

regulations (≥12.0g/100g) while references

suggest that the fiber content of Cookitos is

4.3g/100g [10,11,12]

, indicting it is a source of

fiber,(≥3.0g/100g). It is also low sodium

(<80 mg) and free of trans fat (<0.1 g)[25]

.

Cookitos nutritional information according

to the Brazilian Health Surveillance Agency

- ANVISA[26]

for a portion of 30g is shown

in Figure 2. The shelf life is estimated at 6

months based on similar products already

marketed, suggesting it can be produced in large quantities and widely distributed[27]

. A

preliminary sensory test with 36 panelists ages 5 to 54 years indicated an acceptance of

70%, showing an adequate acceptance in all age groups. The main technological

challenge for better acceptance of the

product is a mild leafy off-flavor

minimized through the use of Brazil nuts.

The taste of Cookitos can still be

improved through the use of cocoa and

guaraná powder and/or flavoring like

vanilla essence, among others. This offers

additional development possibilities for

line extensions generating flavor variety

for children.

1-Eletonic scales 2- pulverizer

3-mixer

4-molding machine 5-Industrial kiln

6- countertop cooling

7- sealing term 8- stainless steel table

9-storing utensils bench

Figure 3- Simplified layout for adjustment of

“ Casas de Farinha”.

A simple layout of a Cookitos processing facility is shown in Figure 3 with a suitable

area to accommodate all production equipment having a spacing area of 60cm between

them and 20cm away from walls. The project encompasses specific area for raw

material and inputs deposit, storage area for finished products, office and expedition,

sized at approximately 110m ².

PROCESSING SAFETY, AND EFFLUENT MANAGEMENT

The production unit shall have an exhaustion system to remove the cyanogenic gases

which may be produced during the processing of cassava to ensure the safety and

welfare of handlers as well as a wastewater treatment system allowing the reuse and the

decrease of environment damage caused by cassava residue. This can be achieved using

an Effluent Treatment Station (STP) [28]

. The effluents are sent to the STP, and the

floating waste removed through the use of grids and mesh, charge neutralization and

separation of the effluent liquid or solid particles by sedimentation and flocculation

processes, anaerobic digestion in sludge from treatment, decanting the aerobic and

anaerobic type in their own ponds and removal of pathogenic microorganisms with a

maturation pond [29]

.

PACKAGING DEVELOPMENT AND ENVIRONMENTAL PROTECTION

Two different packing prototypes were created for Cookitos, the first consisting of a

30g portion (3 units of 10 g each) and the second of a 450g unit (15 units of 30 g each)

intended for family consumption (Figure 4). The packaging prioritizes the safety of the

product and also protects its quality over the shelf life offering mechanical protection,

and protection against light and water vapour, being made of bioriented polypropylene

(BOPP) and aluminum film (individual consumption unit); and cardboard, metallized

film, bioriented polypropylene and polyethylene film (family consumption unit).

Alternative proposals for future improvement of packaging would be the use of sources

that cause less damage to the environment, such as biodegradable materials. Studies

show that it is possible to produce biodegradable packaging from natural resources

found in Brazil such as cassava starch and clay [30]

.

Figure 4: Models of packaging produced to market the individual (left) and family

(right) consumption units.

MARKETING STRATEGY

Cookitos packaging is colorful and fun. Also, it uses images of the Amazon Region

flora and fauna to identify the use of regional raw materials, an exclusivity of the

product. The packaging features a little Indian boy called "papa-chibento", which

alludes to the regional term "papa-chibé", meaning the one who enjoyes regional food;

in order to build consumer identification and affection. The cookie can assume different

shapes such as leaf, fruits (indicating the origin of raw materials used), hearts, and stars

among others, to increase children's interest. Finally, the packaging emphasizes the

superior nutritional properties compared to competing products, featuring front-of-the-

packaging claims that Cookitos is rich in protein, source of fiber and low in sodium. It

can additionally carry the regional organic certification "Pará Organico" provided

suppliers are certified by the entity. To publicize Cookitos, various media can be

considered, especially propaganda in educational television and internet channels,

through the use of 'Jingles' to attract the attention of children who are the main target.

ECONOMIC FEASIBILITY

For the adaptation of flour houses to produce Cookitos, the following equipment is

required: pulverizer, mixer, molding machine, industrial oven, cooling/storage tiers and

shelves; heat-sealing machine, packaging bench, floor scale, bench scales, trays and

tableware in general. A total value estimated in R$ 91,000.00 (approximately U$

39,000.00). This allows a daily production capacity of 533.33 kg / day of cookies,

generating a total annual cost of R$ 1,081,684.08 (U$ 462,258.45). The calculation

takes into account the allotment of production between the two packaging options being

60% for single-serving units and 40% for the family package. It also considers a total of

4 employees working 8 hours a day (single shift) producing a total of 39,110 units per

day (approximately 11,733,140 units / year). The value of the initial investment can be

recovered within a year and each individual unit can be sold for R$ 0.30 (U$ 0.13) and

family packaging for R$ 1.37 (U$ 0.59), totaling a net profit of R$ 1,778,078.20 (U$

759,862,20) per year.

Implementation investment for the project can be partially financed through PRONAF –

The National Program for Family Agriculture Strengthening, which offers grants of up

to R$ 13,500.00 for the interest of 2% per year [6]

. An alternative would be to attract

more investments to create cooperatives among farmers. Cookitos can also be submitted

for distribution by PNAE which benefits 41 million students in Brazil, aged 4-17 with

nutritious food distributed for free at municipal, state and federal primary and secondary

education schools [7]

.

PATENT STATUS

Cookitos is an innovative food because of the use of regional ingredients from the

Amazon of superior nutritional characteristics, which have not been previously used in

combination. According to research at the National Institute of Industrial Property

(INPI) [31]

no patent or licensing rights for similar products were found, not infringing

intellectual property rights. Based on that information, necessary measures have been

initiated for patent registration of Cookitos at the Federal University of Pará - Brazil.

SCOPE AND POTENTIAL USE IN OTHER REGIONS

The production of Cookitos has potential to be adopted by other regions of Brazil and

even the world, where cassava is the staple food in places that have a low protein diet.

The product formulation is flexible and can be adapted through the use of other

ingredients according to the availability in each region or country. In exemple, Brazil

nuts can be substituted for cashews or pine nuts easily found in other parts of the

country [32]

; whereas in Africa and Indonesia peanuts can be used [33]

. Finally, marketing

strategies can also be adapted to local cultures to attract the target market.

CONCLUSION

This project explored the development and production of Cookitos, a product made

from indigenous raw materials of the Amazon Region to address child malnutrition. The

adaptation of flour houses to process products with higher added value, rich in protein,

source of fiber and low in sodium is highly feasible and enables the improvement of

diets and growth of the local economy. In conclusion, the project can also be adapted by

other Regions producing Cassava in Brazil and around the world.

ACKNOWLEDGEMENTS

We acknowledge the valuable contributions of Professor Alessandra Santos Lopes.

This project was kindly supported by the National Counsel of Technological and

Scientific Development - CNPQ and The Pará Amazon Foundation for Research

Support – FAPESPA.

Appendix A –Cookitos Processing Flow Chart.

RECEPTION

Brazil nuts Mandioc leaves Pupunha Passion fruit bark Banana Ingredientss

/packing

Cleaning and

sanitizing(CCP2)*

Cleaning and

sanitizing(CCP2)*

Cleaning and

sanitizing(CCP2)*

Cleaning and

sanitizing(CCP2)*

Cleaning and

sanitizing(CCP2)*

Shelling Drying (CCP3)*

Cooking Pulping Pulping

Milling Cooling Pulping

Drying the Peel

(CCP5)*

Drying (CCP5)*

Pressing Pulverizing(CCP4)* Drying(CCP5)* Cooling Cooling

Drying the Cake

(CCP5)* Storage

Cooling Pulverizing Pulverizing

Cooling

Pulverizing Storage Storage

Pulverizing

Storage

Storage

Weighing cookie

ingredients

Mixing the

ingredients

Shaping/ Sheeting

Baking (CCP6)*

Cooling

Packing

Metal detection

(CCP7)*

Storage

* Details about the hazards and critical points of the process and their corrective actions

are detailed in the table 1.

(8 hours, 30°C, shade)

(24 hours, 60°C) (15 minutes)

(45 minutes, 100°C)

(30 minutes 25-27°C)

( 30 minutes 25-27°C) ( 30 minutes 25-27°C)

(CCP1)*

(24 hours, 60°C) (48 hours, 60°C)

( 30 minutes 25-27°C)

(48 hours, 60°C)

15 minutes, 200°C

aw ≤ 0,5

30 minutes, 25-27°C

( 30 minutes 25-27°C)

5 minutes

( 30 minutes 25-27°C)

Appendix B

TABLE 1- COOKITOS HACCP PLAN

CCP Hazard Critical Limit Monitoring Corrective Action Verification / Registration

Receiving cookie raw

materials, ingredients

and packing materials

CCP1

Physical Hazard (metal and foreign

objects); Biological Hazard (incoming

bacteria, yeast, mold); Chemical Hazard

(incoming pesticides and information

about gluten and allergens in the packing

materials).

Limits within the

standards established

by ANVISA [34].

Review of supplier

certificates, control of

specifications and visual

control of imputs upon

receiving.

Rejection of lot and/or

change of suppliers.

Record keeping and verification of

certificates and control of

specifications.

Cleaning and sanitizing

CCP2

Biological Hazard (log reduction of

incoming bacteria, yeast, mold).

Minimum quantity ≥10

ppm [17].

Testing kit/ chlorine

addition log and analysis. Wash again or reject lot. Record keeping and verification of

chlorine addition log and analysis.

Drying

(Cassava leaves)

CCP3

Chemical Hazard (toxic cyanogenic

glucosides).

8 hours at 30° in the

shade

Maximun quantity:

100mg/kg [24]

.

Quantication of

cyanogenic glucosides for

every lot.

Rejection of lot and/or

change of suppliers.

Record keeping and verification of

drying temperature logs and certificate

of analysis.

Pulverizing

(Cassava leaves)

CCP4

Chemical Hazard (toxic cyanogenic

glucosides).

Pulverizing for 15

min

Maximun quantity:

100mg/kg [24]

.

Quantication of

cyanogenic glucosides for

every lot.

Rejection of lot and/or

change of suppliers.

Record keeping and verification of

pulverization temperature logs and

certificate of analysis.

Drying

(raws materials)

CCP5

Biological Hazard (remainder bacteria,

yeast, mold).

humidity less than

35%

60°C for 24-48 hours [18]

.

Keep track of temperature

and time heating every 30

min.

Additional drying to

obtain the desired final

moisture/aw.

Record keeping and verification of

heating temperature logs and final

moisture/aw.

Baking (Cookie)

CCP6

Biological Hazard (presence of excess

water).

aw of Cookie must be ≤

0,5

15 minutes, 200°C.

time and temperature logs;

aw analysis of every lot.

Non compliant products

should be additionally

cooked.

Record keeping and verification of

aw, time and temperature logs.

Metal detector

CCP7

Physical Hazard (presence of metals). Metal thickness ≤

1mm.

Testing every 2 hours with

metal > 1mm.

Rejection of lot until the

device is fixed .

Record keeping and verification of

metal detector logs.

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