Chapter 4 - Quality Assurance for Corn and Wheat Flour Tortilla Manufacturing

Abstract

Quality assurance (QA) is critical in both corn and wheat flour tortilla operations because it is key to providing safe products to consumers and maintaining products within the established standards given by regulatory agencies. An effective QA and quality control (QC) program should prevent defects and chronic waste, keep good quality records, establish a trace recall program, and improve shelf life. QA/QC improves shelf life by monitoring pH, moisture, storage conditions, initial microbial load, and preservative type and concentration. Responsibilities of QA/QC personnel also include production forms, returns, receiving, food safety and HACCP, allergen programs, labeling, and supplier certification. The corn and wheat flour tortilla industries have developed numerous assays to control the quality of raw materials and the intermediate and end products. The quality of both corn and wheat raw kernels is tested similarly to quality in other milling industries. The main quality control parameters for fresh masa and dry flours are particle size distribution, water absorption, water solubility, viscosity, color, and pH. Likewise, the principal quality measurements for wheat flour tortillas are dough rheological properties determined with the Farinograph, Alveograph, Mixolab, and related instruments. Both types of tortillas (fresh and stored) are tested for rollability, roundness, thickness, appearance, sticking, specific volume, pH, moisture, titratable acidity, texture, color, and sensory characteristics. The resulting tortillas are optimal for determining chemical composition and microbial and textural shelf life at different storage conditions.