INDUSTRIAL PROJECT THE DESIGN OF A HACCP PLAN FOR THE ISA DAIRY PLANT DECEMBER 2008 A report work by:
Jenifer Lourdu Edward, Ravichandran Suresh & Sunil Pachar Master 2- Industrial Biotechnology Management Management Research Advisors: Celine Casagrande and Cecile Goutte
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INDUSTRIAL PROJECT THE DESIGN OF A HACCP PLAN FOR THE ISA DAIRY PLANT DECEMBER 2008 A report work by:
Jenifer Lourdu Edward, Ravichandran Suresh & Sunil Pachar Master 2- Industrial Biotechnology Management Management Research Advisors: Celine Casagrande and Cecile Goutte
1
INDUSTRIAL PROJECT THE DESIGN OF A HACCP PLAN FOR THE ISA DAIRY PLANT DECEMBER 2008 A report work by:
Jenifer Lourdu Edward, Ravichandran Suresh & Sunil Pachar Master 2- Industrial Biotechnology Management Management Research Advisors: Celine Casagrande and Cecile Goutte
1
ABSTRACT
Title: The Design of a HACCP Plan for the ISA Dairy Plant
Writers: Jenifer Lourdu Edward,
Ravichandran Suresh & Sunil Pachar
Research Advisors: Celine Casagrande,
Cecile Goutte
Date: December 2008
No. Of Pages: 52
2
ACKNOWLEDGEMENTS
We sincerely thank Celine Casagrande and Cecile Goutte, our research advisers for their professional direction and the time they spent with us to complete this study successfully.
In addition we would also like to express our gratitude to Mr. Tanguy Bantas for guiding us the HACCP procedures. procedures.
Finally, we thank ISA for entrusting us with this project and it has been a wonderful experience working for them.
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TABLE OF CONTENTS
1. INTRODUCTION INTRODUCTION ............................................................................................. ...................................................................................................................................... ......................................... 10 2. PURPOSE OF STUDY .......................................................................................................................... ............................................................................................................................... ..... 11 2.1 Statement of the study .................................................................................................................... .................................................................................................................... 11 2.2 Needs for the study.......................................................... .......................................................................................................................... ................................................................ 11 2.3 Objectives.......................... Objectives................................................................................................... ............................................................................................................... ...................................... 11 2.4 Problems Encountered .................................................................................................................... .................................................................................................................... 11 3. METHODOLOGY METHODOLOGY & RESULTS............................................................... ................................................................................................................... .................................................... 12 3.1 Principles of HACCP.......................................................... .......................................................................................................................... ................................................................ 12 3.2 Application .............................................................................................. ....................................................................................................................................... ......................................... 13 3.2.1 Assemble HACCP team .......................................................... .............................................................................................................. .................................................... 13 3.2.2 Describe product................................................................... ....................................................................................................................... .................................................... 14 3.2.3 Identify intended use ........................................................................................................... ................................................................................................................ ..... 19 3.2.4 Construct flow diagram......................................................... ............................................................................................................. .................................................... 19 3.2.5 On-site confirmation of flow diagram....................................................................................... diagram....................................................................................... 20 3.2.6 List all potential hazards associated with each step, conduct a hazard analysis, and consider any measures to control identified hazards ...................................................................................... 20 3.2.7 Determine Critical Control Points ........................................................................................ ............................................................................................. ..... 23 3.2.8 Establish critical limits for each CCP ......................................................................................... 24 3.2.9 Establish a monitoring system for each CCP ........................................................................ ............................................................................. ..... 24 3.2.10 Establish corrective actions ........................................................... .................................................................................................... ......................................... 25 3.2.11 Establish verification procedures.............................................................. ............................................................................................ .............................. 26 3.2.12 Establish Documentation Documentation and Record Keeping .................................................................. ....................................................................... ..... 26 4. RECOMMENDATIONS RECOMMENDATIONS............................................................. ............................................................................................................................. ................................................................ 26 5. CONCLUSION CONCLUSION ........................................................................... .......................................................................................................................................... ............................................................... 28 4
ANNEX ..................................................................................................................................................... 29 Logic Sequence for Application of HACCP (Diagram 1) ....................................................................... 29 Hazards in Ingredients & Incoming Materials Analysis Chart (Chart 1) .............................................. 30 Hazard Analysis Chart for Cheese Processing (Chart 2) ........................................................................ 32 Risk Assessment for determined hazards (Chart 3) ................................................................................. 38 HACCP Decision tree utilized to determine the critical control points (Diagram 2) ............................. 42 Critical Control Point determination using the decision tree (Chart 4) ................................................. 43 Chart displaying the critical limits for each CCP (Refer Annex, Chart 5) ............................................. 49 6. BIBLIOGRAPHY ....................................................................................................................................... 52
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\ LIST OF DEFINITIONS
Cleaning - the removal of soil, food residue, dirt, grease or other objectionable matter.
Contaminant - any biological or chemical agent, foreign matter, or other substances not intentionally added to food which may compromise food safety or suitability.
Contamination - the introduction or occurrence of a contaminant in food or food environment.
Disinfection - the reduction, by means of chemical agents and/or physical methods, of the number of micro-organisms in the environment, to a level that does not compromise food safety or suitability.
Establishment - any building or area in which food is handled and the surroundings under the control of the same management.
Food hygiene - all conditions and measures necessary to ensure the safety and suitabilit y of food at all stages of the food chain.
Hazard - a biological, chemical or physical agent in, or condition of, food with the potential to cause an adverse health effect.
Food handler - any person who directly handles packaged or unpackaged food, food equipment and utensils, or food contact surfaces and is therefore expected to comply with food hygiene requirements.
Food safety - assurance that food will not cause harm to the consumer when it is prepared and/or eaten according to its intended use.
Control: To take all necessary actions to ensure and maintain compliance with criteria established in the HACCP plan.
Control measure: Any action and activity that can be used to prevent or eliminate a food safety hazard or reduce it to an acceptable level.
Corrective action: Any action to be taken when the results of monitoring at the CCP indicate a loss of control.
Critical Control Point (CCP): A step at which control can be applied and is essential to prevent or eliminate a food safety hazard or reduce it to an acceptable level. 6
Critical limit: A criterion which separates acceptability from unacceptability.
Deviation: Failure to meet a critical limit.
Flow diagram: A systematic representation of the sequence of steps or operations used in the production or manufacture of a particular food item.
HACCP: A system which identifies, evaluates, and controls hazards which are significant for food safety.
HACCP plan: A document prepared in accordance with the principles of HACCP to ensure control of hazards which are significant for food safety in the segment of the food chain under consideration.
Hazard: A biological, chemical or physical agent in, or condition of, food with the potential to cause an adverse health effect.
Hazard analysis: The process of collecting and evaluating information on hazards and conditions leading to their presence to decide which are significant for food safety and therefore should be addressed in the HACCP plan.
Monitor: The act of conducting a planned sequence of observations or measurements of control parameters to assess whether a CCP is under control.
Step: A point, procedure, operation or stage in the food chain including raw materials, from primary production to final consumption.
Validation: Obtaining evidence that the elements of the HACCP plan are effective.
Verification: The application of methods, procedures, tests and other evaluations, in addition to monitoring to determine compliance with the HACCP plan.
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LIST OF TABLES & FIGURES
Table 1: Illustrates the plan of action undertaken to implement the HACCP plan for the dairy plant. (Page 12)
Table 2: Displays the product characteristics for Tomme cheese and St. Paulin cheese. (Page 16)
Table 3: Allergen information for Tomme cheese and St.Paulin cheese. (Page 17)
Figure 1: The process flow diagram for both Tomme cheese and St. Paulin is given along with the CCP’s determined. (Page 18)
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LIST OF ABBREVIATIONS
HACCP: Hazard Analysis Critical Control Point
NASA: National Aeronautics and Space Administration
ISA: Institut Superieur d’Agriculture
CCP: Critical Control Point
CP: Control Points
PRP: Pre Requisite Program
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1. INTRODUCTION HACCP is an acronym for the Hazard Analysis Critical Control Point. It is a system that was developed for assuring pathogen-free foods for the space program by the Pillsbury Company, the U.S. Army, and the National Aeronautics and Space Administration (NASA) in the 1960s.
The dairy plant at ISA, which produces curd and cheese requires a HACCP plan for its quality control program and also since it is mandatory in the European Union. The scope of this project was to establish a HACCP model for the cheese products produced here at this plant. Cheese is a product that preserves raw milk. Due to the high acidity (low pH value) in the cheese-making process, the pathogens in the milk are killed. However, in cheese manufacturing, problems associated with the presence of Listeria monocytogenes, Salmonella enteritidis, Staphylococcus aureus, Escherichia coli and others have been documented. HACCP was originally developed as a “zero defects” program and considered to be synonymous with food safety. It is a straightforward and logical system that uses preventative action to address potential microbiological, chemical and physical hazards that are identified in the process. HACCP is a science-based system used to ensure that food safety hazards are controlled to prevent unsafe food from reaching the consumer.
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2. PURPOSE OF STUDY 2.1 Statement of the study The purpose of this study is to design a HACCP plan model for a small scale dairy plant at ISA. th
th
This study started on the 15 of October and finished on the 12 of December, 08. The study has been carried out by making observations of the plant environment, and by discussing potential hazards and other recommendations with the cheese maker and HACCP experts in order to develop the specific HACCP model.
2.2 Needs for the study This study is specifically designed for a small-scale cheese plant which has just recently started functioning and that needs a better quality control system to produce quality, safe cheese.
2.3 Objectives To set up a specific HACCP plan for this small-scale dairy plant and to document the HACCP plan in order to demonstrate the effectiveness of its application.
2.4 Problems Encountered The project spanned for a very limited time and thereby as a result of time constraint a few experiments could not be carried out (Analysing the chlorine content in water used for cheese manufacturing). Also the production of cheese did not take place during this period; this r esulted in us having a very limited knowledge about the production method in this plant. Nevertheless, we committed ourselves in finding the most appropriate HACCP model for this plant in consultation with our advisers and HACCP experts.
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3. METHODOLOGY & RESULTS This chapter will discuss the approach we undertook in order to implement the HACCP for the dairy plant; utilizing the principles and application of HACCP, we have established the HACCP plan with relevance to cheese making. It will conclude with a report of findings of the significance of HACCP on cheese processing.
3.1 Principles of HACCP The HACCP system consists of the following seven principles: PRINCIPLE 1 Conduct a hazard analysis. PRINCIPLE 2 Determine the Critical Control Points (CCPs). PRINCIPLE 3 Establish critical limit(s). PRINCIPLE 4 Establish a system to monitor control of the CCP. PRINCIPLE 5 Establish the corrective action to be taken when monitoring indicates that a particular CCP is not under control. PRINCIPLE 6 Establish procedures for verification to confirm that the HACCP system is working effectively. PRINCIPLE 7 Establish documentation concerning all procedures and records appropriate to these principles and their application.
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3.2 Application The application of HACCP principles consists of the following tasks as identified in the Logic Sequence for Application of HACCP (See Annex, Diagram 1).
3.2.1 Assemble HACCP team
HACCP Team a) Jenifer Lourdu Edward b) Ravichandran Suresh c) Sunil Pachar The team also included our research guides namely Celine Casagrande, Cecile Goutte and also Tanguy Bantas (HACCP expert).
The scope of the study was to implement a HACCP plan for two varieties of cheese produced at this site namely Tomme Cheese and St. Paulin and to check its efficiency during its next production. All classes of hazards were put to study during this project (Biological, Chemical and Physical).
Plan of Action
Action PRP Description Description of Product Composition Physical/Chemical Structure Microcidal/Static Temperatures Packaging Storage Conditions Distribution Methods Intended use of Product Construct the flow diagram and describe the process. Design of Building On Site Verification Hazard Analysis Biological 13
Person in Charge Jenifer, Sunil
Date th nd 15 to 22 Oct, 08
Suresh Suresh Sunil Sunil Jenifer Jenifer Suresh Suresh Description) Jenifer
22
Sunil
15/10/08 15/10/08 15/10/08 15/10/08 15/10/08 15/10/08 15/10/08 th nd (Process 15 to 22 Oct, 08 nd
th
15
Oct, 08
Oct to 19
th
Physical
Jenifer
Chemical
Suresh Jenifer, Sunil, Suresh Jenifer, Sunil, Suresh Jenifer, Sunil, Suresh Jenifer, Sunil, Suresh
Risk Assessment Determining CCP’s Establishing Critical Limits Monitoring System for CCP’s Corrective Actions Verification Procedures Documentation Time for report completion Report Submission
N/A N/A Jenifer, Sunil, Suresh
Nov, 08 th th 15 Oct to 19 Nov, 08 th th 15 Oct to 19 Nov, 08 19/11/08 th Nov 19 to 26th th Nov 19 to 26th th Nov 19 to 26th
st
th
Dec 1 to 9 th December 12
Table 1: Illustrates the plan of action undertaken to implement the HACCP plan for the dairy plant.
3.2.2 Describe product
Tomme Cheese: Process Description
Cheese making is the process of removing water, lactose and some minerals from milk to produce a concentrate of milk fat and protein. The essential ingredients for cheese are milk, rennet, starter cultures and salt. The semi-form gel is formed by adding rennet that causes the milk protein to aggregate at a certain pH; then it is cut into small curds. Then the whey (mostly water and lactose) begins to separate from the curds. Acid production from bacterial cultures is essential to aid in the expulsion of whey from the curd and largely determines the final cheese moisture, flavour and texture. The production of Tomme Cheese (a half-pressed and uncooked cheese made with pasteurized cow’s milk) involves: The milk is kept chilled (< 4 ⁰C) in storage tanks prior to production. Before pasteurization, the milk is passed through heat exchangers (~ 35 ⁰ to 40⁰ C) and then moved into the pasteurization tank. 1. Pasteurization
Pasteurization is one of the most important critical control points in the cheese making process. It helps to increase the shelf life of the product by destroying vegetative 14
pathogens in milk. The milk is pasteurized at 72 ⁰C for a minute. The pasteurized milk is then cooled down to 30 ⁰C in the pasteurization tank. 2. Stirring
Two pitchers of 1 l each are taken and into each the starter cultures (Sigma 41 and Omega) is diluted (1 tube) with the pasteurized milk taken from the tank. The use of cultures in cheese making is to develop acidity and to promote ripening. It is then poured into the tank along with Calcium Chloride solution (32 mL) and stirred for 2 minutes at high speed in the tank. 3. Ripening
Ripening refers to the practice of giving the culture time to begin acid production before the rennet is added. Ripening is done to ensure the culture is active before the milk is renneted and development of acidity aids the coagulation process. The stirred milk is left for ripening in the pasteurization tank for 2 hours at 30 ⁰C. 4. Addition of Rennet
Casein is the major protein in milk. During cheese production, rennet (25 mL /100 L of milk), a coagulating enzyme, is stirred into the milk at 30 ⁰C for 50 minutes. Under certain acid condition, rennet then separates the casein from the whey and causes the individual cells of the casein to clump together to form the gel network. 5. Cutting the curded milk
At the beginning, cut to obtain cheese grain as big as corn grain. Wait a few minutes until the whey rises to the surface. Blend with the cutting equipment for 30 minutes. Wait for a few minutes and then remove 15 L of whey after which 15 L of water is added. It is then blended for 10 to 20 minutes. 45 L of whey is then removed for the curd to remain. 6. Moulding
The curd is placed in the moulds. The moulds are placed on a tra y under the exit valve of the pasteurization tank. The valve is opened for the curd to drain into the moulds through the shovel. 15
7. Pressing
Pressing the mass helps to form loose curd particles into a compact mass and expel whey. Pressing is performed by placing the lids (flat upside down) on top of the wrapped curds. A stainless plate is used to segregate each layer of curd (Each layer contains 3 moulds of curd). The cheese is pressed at 2 bars for 1 hour and then turned over and the same action is repeated. A vessel is placed under the press mould to collect the expelled whey. After pressing the cheese, the moulds are removed. 8. Salting
The purpose of salting is to inhibit: the growth and activity of food poisoning and pathogenic micro-organisms; the activity of various enzymes in cheese; reduce the moisture of cheese; change cheese proteins which influence cheese texture and protein solubility; and affect cheese flavour. Salting of cheese is carried out by filling buckets with water and salt (300g of salt/ L of water) at 15⁰C. Place the cheese in the buckets for 10 hours in the ageing cellar and maintain a temperature of 16⁰C to 18⁰C. 9. Maturation
Cheese maturation exposes the prepared cheese to certain environmental conditions (temperature, humidity and so on) for several months to several years depending on the cheese type. The purpose is to break down the proteins, lipids and carbohydrates (acids and sugars) which releases flavour compounds and modifies cheese texture. Remove the cheese from buckets and place on plate racks in the ageing cellar (14 ⁰C to 16⁰C for 24 hours). Place buckets with water in the ageing cellar in order to get approximately 95% hygrometry (11⁰C to 14⁰C for a month). Turn the cheese over every st
2 days for the 1 week and then once a week. From the 3 rind each time it is turned over.
16
rd
week on, brush the cheese
Product Description
Product Name
Cheese Tomme
Composition
Raw Milk, Starters (Sigma 41 and Omega), Rennet, Calcium Chloride, Salt, Water
Product Characteristics
Water Activity & Moisture Content (To be determined),
Usage and Consumption
Who: Children, adults and old people When: Any time of the year How: Ready to eat Where: Small scale distribution
Packaging
To be determined
Shelf Life
To be determined
Labelling Instruction
Keep refrigerated
Distribution Condition
Refrigerated
GMO Information
No GMO in the product
Table 2: Displays the product characteristics for Tomme cheese and St. Paulin cheese.
For the production of St.Paulin cheese the production method is the same except that the starter cultures used are different (Omega and Lambda, Sigma 96 and lota 7 respectively)
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Allergen Information
Intentional presence
Cereals
Non intentional presence
with gluten and products with NO
cereals with gluten
NO
Crustaceans and products with crustaceans
NO
Eggs and products with eggs
NO
Fish and products with fish
NO
Peanuts and products with peanuts
NO
Soya and products with soya
NO
Milk and dairy products (lactose too)
YES
Fruits with shell and derived products
NO
Sesame seed and products with sesame seed
NO
Sulphites in concentration of 10 mg/kg
NO
The dairy plant produces only cheese and curd, so there is no risk of cross contamination with other ingredients.
Table 3: Allergen information for Tomme cheese and St.Paulin cheese.
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3.2.3 Identify intended use It is a ready to eat product which can be consumed by the young, old, pregnant and immunecompromised individuals.
3.2.4 Construct flow diagram Pasteurisation of raw milk (72⁰C for 1 minute) (CCP-1 B) Cool down to 30 ⁰C Take pasteurized milk, put it in a pitcher & add Sigma 41 and Omega respectively (Tomme Cheese)
Stirring (2 minutes at high speed)
Ripening (30⁰C for 2 hours)
Renneting (30⁰C for 50 minutes)
Rennet (25 mL/1000 L 1. of milk) (CCP-2 B)
Take pasteurized milk, put it in a pitcher and add Omega and Lambda, Sigma 96 and lota 7 respectively (St.Paulin Cheese) Calcium Chloride 32 mL
Removal of whey, cutting the curded milk Moulding Pressing (P=2 Bar)
Weigh salt (300 g/L of water (CCP-3 B)
Removing cheese from moulds
Fill buckets with salt + water at 15⁰C
Salting (Place cheese in buckets) 16⁰ C to 18⁰C for 10 hours (in the ageing cellar)
Maturation in the ageing cellar 19 (CCP-4 B)
Use sterilized cloth
*The CCP’s have been identified numerically and all the CCP’s are Biological Hazards (abbreviated as B).
Figure 1: The process flow diagram for both Tomme cheese and St. Paulin is given along with the CCP’s determined.
3.2.5 On-site confirmation of flow diagram The process flow diagram for cheese had already been validated and provided to us to implement the HACCP plan.
3.2.6 List all potential hazards associated with each step, conduct a hazard analysis, and consider any measures to control identified hazards (SEE PRINCIPLE 1)
The hazard analysis was carried out from the receival of raw milk in cans from the milk producer and until maturation. The possible biological, chemical and physical hazards were determined for each step in the process and preventive measures to control the hazards were formulated. After the analysis of the hazards, risk assessment was carried out to determine the severity of the determined hazards. The risk assessment enables us to know how severe the hazards are and their occurrence levels. With the knowledge of the risk assessment scores, the potential CCP’s can be predicted and then the risks can be controlled by utilizing control points (CP) or Critical Control Points (CCP’s) to reduce the risks.
Hazards in Ingredients & Incoming Materials Analysis Chart (Refer Annex: Chart 1)
Ingredient
Hazards
Preventive Measures
and Material
Raw
Receival
Biological: Milk
Bacteriological PRP:
Supplier
should
containing milk are unclean.
cleanable and which are sanitized
20
buckets
manufacturer
contamination can occur if the buckets
properly.
use
and
which
are
Physical: Presence of foreign bodies
PRP: Qualified supplier.
Chemical: Presence of antibiotics will
PRP: Supplier should adhere to good
inhibit the growth of starter cultures
herd practices.
making the curd soft and floppy.
Hazard Analysis Chart for Cheese Processing (Refer Annex: Chart 2)
Processing Step
Hazards
Preventive Measures
Passage of milk through the Biological: None heat Exchanger
Physical: None Chemical: Traces of cleaning and
PRP:
disinfecting chemicals
sanitation
Proper
Risk Assessment
Risk = Estimation of probability Risk Assessment: S*O Where S: Seriousness Index O: Occurrence/Frequency Index
Hazards with low probability or with low severity should not be included in the HACCP plan
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They will be managed with the PRE REQUISITE which are the Good Manufacturing Practices (GMPs) 2
1
3
FRE UENCY
1
I.
II.
III.
II.
III.
IV.
III.
IV.
IV.
2
3
SEVERITY
I.
No Risk: Controlled through PRP Low Risk : Controlled through GMP’s
II. III.
Moderate Risk : Controlled through establishing CCP’s
IV.
High Risk: No control measures
Risk Assessment for determined hazards (Refer Annex: Chart 3)
Processing
Hazards
Risk
Step
Assessment
Raw
Receival
S
F
S*F
2
2
III.
1
2
II.
Chemical: Presence of antibiotics will inhibit the growth of 2
1
II.
Biological: Bacteriological contamination can occur if the Milk buckets containing milk are unclean. Physical: Presence of foreign bodies
starter cultures making the curd soft and floppy.
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3.2.7 Determine Critical Control Points (SEE PRINCIPLE 2)
There may be more than one CCP at which control is applied to address the same hazard. The determination of a CCP in the HACCP system can be facilitated by the application of a decision tree (Refer Annex: Diagram 2) , which indicates a logic reasoning approach. It should be used for guidance when determining CCPs. If a hazard has been identified at a step where control is necessary for safety, and no control measure exists at that step, or any other, then the product or process should be modified at that step, or at any earlier or later stage, to include a control measure. After determining the CCP’s, it should be positioned in the flow diagram at the appropriate step and must be identified numerically and the category of hazard that is addressed should be précised (B for Biological, C for Chemical and P for Physical). Ex. CCP-1 B. The CCP controls should be continuous, well specified, registered and the results must be produced before the cheese leaves the plant.
With the aid of the decision tree four CCP’s have been established and all identif ied are biological hazards which are marked in the flow diagram.
Critical Control Point determination using the decision tree (Refer Annex: Chart 4)
Processing Step
Hazards
Q1
Q2
Q3
Q4
Conclusion
(Y/N)
(Y/N)
(Y/N)
(Y/N)
(CCP
or
not)
Raw
Receival
Yes
No
Yes
Yes
Not a CCP
of Yes
No
No
-
Not a CCP
of Yes
No
No
-
Not a CCP
Biological: Milk
Bacteriological contamination can occur if the buckets containing milk are unclean. Physical:
Presence
foreign bodies Chemical:
Presence
antibiotics will inhibit the growth of starter cultures 23
making the curd soft and floppy.
3.2.8 Establish critical limits for each CCP (SEE PRINCIPLE 3)
Critical limits must be specified and validated for each Critical Control Point. In some cases more than one critical limit will be elaborated at a particular step. Criteria often used include measurements of temperature, time, moisture level, pH, Aw, available chlorine, and sensory parameters such as visual appearance and texture. These critical limits should be measurable.
Chart displaying the critical limits for each CCP (Refer Annex, Chart 5)
HAZARD
Pathogenic
Bacteria
(Non
CCP
CRITICAL LIMIT
Pasteurization (CCP-1 B)
Pasteurize milk at 72⁰C for
Sporulating)
1minute. (+/- 2⁰C)
3.2.9 Establish a monitoring system for each CCP (SEE PRINCIPLE 4)
Monitoring is the scheduled measurement or observation of a CCP relative to its critical limits. The monitoring procedures must be able to detect loss of control at the CCP. Further, monitoring should ideally provide this information in time to make adjustments to ensure control of the process to prevent violating the critical limits. Where possible, process adjustments should be made when monitoring results indicate a trend towards loss of control at a CCP. The adjustments should be taken before a deviation occurs. Data derived from monitoring must be evaluated by a designated person with knowledge and authority to carry out corrective actions when indicated. If monitoring is not continuous, then the amount or frequency of monitoring must be sufficient to guarantee the CCP is in control. Most monitoring procedures for CCPs will need to be done rapidly because they relate to online Processes and there will not be time for lengthy analytical testing. Physical and chemical Measurements are often preferred to microbiological testing because they may be done rapidly and can often indicate the microbiological control of the product.
24
All records and documents associated with monitoring CCPs must be signed by the person(s) doing the monitoring and by a responsible reviewing official(s) of the plant.
Chart displaying monitoring procedures to control critical limits during process (Refer Annex: Chart 6)
CCP
Pasteurization (CCP-1 B)
HAZARDS
PREVENTIVE MEASURES Pathogenic Pasteurize milk at 72⁰C Bacteria (Non for 1 minute to destroy Sporulating) the pathogens and control the temperature by using a glass thermometer. Ensure equipment is adequately maintained, correctly calibrated and serviced every 3 months.
CRITICAL MONITORING LIMITS PROCEDURES Pasteurize Who? User milk at 72⁰C for 1minute. (+/- 2⁰C)
How?
Check with another thermomete r
When?
During production
3.2.10 Establish corrective actions (SEE PRINCIPLE 5)
Specific corrective actions must be developed for each CCP in the HACCP system in order to deal with deviations when they occur. The actions must ensure that the CCP has been brought 25
under control. Actions taken must also include proper disposition of the affected product. Deviation and product disposition procedures must be documented in the HACCP record keeping.
3.2.11 Establish verification procedures (SEE PRINCIPLE 6)
Verification procedures to check the validity of the HACCP and the proper operation of the plan would be carried out by the cheese maker during the next production run.
3.2.12 Establish Documentation and Record Keeping (SEE PRINCIPLE 7)
To establish documentation and record keeping the support of our HACCP plan would be looked into by the cheese maker in order to prove the product is safe, for the purpose of inspection, for traceability, to monitor the system and is a basis for continuous improvement.
4. RECOMMENDATIONS Hygiene Design
In the current setup at the dairy plant there is a possibility of cross-contamination as shown in the process flow diagram as the flow of employees may cause contamination during storage of cheese in the ageing cellar.
Since the ageing cellar is closed the frequency of cross contamination is low.
But according to the requirements of HACCP, the process flow in a building should not overlap each other.
Hence we would like to propose to shift the tank storage rack next to the curd receiver. And there by shifting the ageing cellar nearby salting area.
This results in a healthy process flow without any cross contamination. RECEIVING CURD PASTEURIZATION & CHEESE PRODUCTION SKIMMING WASHING
HEAT 26
EXCHANGING STORAGE OF MILK
STORAGE OF TANKS PRESSING
ENTRANCE
PROCESS FLOW – CURRENT SET UP
OUR PROPOSAL: Place the Storage rack here
27
Place ageing cellar here
5. CONCLUSION The validated HACCP plan is a first of a kind in this plant and its effectiveness would be checked during the next production run. On the basis of continual improvement it is always important to have a HACCP plan and evolve from it. The model is developed step-by-step based on the seven principles of HACCP system mentioned in the literature review. The prerequisite program was provided to deal with some hazards before the production; therefore, to simplify the HACCP plan. The product description was used to alert the consumer to the potential hazards in the final products. Then, the potential control points of the hazards appeared in both raw material and the process will be studied along with the prevention measures. By answering the questions in the decision trees, the critical control points were determined. Finally, the HACCP control chart was developed to include components of several HACCP principles which are critical limits, monitoring and responsibility. Four CCP’s were found in the production in this cheese plant. They are: 1. Pasteurization (CCP-1 B) 2. Monitoring of pH (CCP-2 B) 3. Proper dilution of salt and water; monitoring the temperature of water (CCP-3 B) 4. Monitoring of temperature and pH. (CCP-4 B)
28
ANNEX Logic Sequence for Application of HACCP (Diagram 1)
29
Hazards in Ingredients & Incoming Materials Analysis Chart (Chart 1) Ingredient
Hazards
Preventive Measures
30
and Material
Raw
Receival
MilkBiological: Bacteriological contamination
PRP: Supplier and manufacturer
can occur if the buckets containing milk should are unclean.
use
buckets
which
are
cleanable and which are sanitized properly.
Physical: Presence of foreign bodies
PRP: Qualified supplier.
Chemical: Presence of antibiotics will
PRP: Supplier should adhere to
inhibit the growth of starter cultures
good herd practices.
making the curd soft and floppy.
Raw
MilkBiological: Improper temperature and
Store < 4⁰C for a maximum of 7 to
Storage
time controls can lead to vegetative
10 days so as to minimise the
pathogens and spoilage microorganisms
growth of vegetative pathogens.
multiplying to levels that may be capable
(When possible it is advised to use
of
the milk within 36 hours after
overwhelming
the
pasteurization
process
milking)
Biological: Milk is stored in tanks that, if PRP: Follow Pre -SSOP’s & Post-
unclean,
can
result
in
bacterial
SSOP’s
contamination.
Physical: None Chemical:
Traces
of
cleaning
disinfecting chemicals
31
and
PRP: Proper Sanitation
Starter
Biological: Starter cultures susceptible to
Cultures
strains of bacteriophages.
PRP: Qualified product supply.
Physical: None Chemical: None
Rennet
Biological: None Physical: None Chemical: None
Water
Biological: Presence of bacteria, virus or
PRP: Qualified water suppliers.
protozoan’s can lead to illness. Physical: None Chemical: Presence of chlorine. (2 ppm
Test for free chlorine in water by
of chlorine will destroy 40% of rennet
test strip method. (Frequency)
activity in 3 minutes) Salt
Biological: None Physical: Presence of foreign particles Chemical: None
Hazard Analysis Chart for Cheese Processing (Chart 2) 32
PRP: Purchase of quality product.
Processing Step
Hazards
Preventive Measures
Passage of milk through the Biological: None heat Exchanger
Physical: None Chemical:
cleaning
Traces and
of PRP: Proper sanitation
disinfecting
chemicals
Pasteurization
Biological:
Pathogenic
microorganisms
( Bacillus minute
cereus,
Listeria
monocytogens
,
enterocolitica,
spp.,
O157:H7,
Pasteurize milk at 72 ⁰C for 1 to
destroy
the
pathogens and control the
Yersinia temperature by using a glass
Salmonella thermometer.
Escherichia
Campylobacter
jejuni) may survive due to
improper
pasteurization
coli Ensure
equipment
adequately correctly
is
maintained, calibrated
and
serviced every 3 months.
temperature and control.
Physical: None Chemical:
cleaning
Traces and
of PRP: Proper Sanitation
disinfecting
chemicals. Stirring
Biological: 1) Starter cultures
may act slowly due to low Addition of Omega and temperature of milk which Sigma 41 starter cultures results in microbiological along with Calcium contamination as time 33
1) Genus Lactococcus & Leuconostoc
require
the
temperature of milk to be 20⁰ to 40⁰ C for it to activate and for
Streptococcus
Chloride
Solution
for
Tomme Cheese production
Addition
of
progresses and too high a
temperature for milk may 35⁰ to 41⁰C for it to activate.
inactivate the starter culture. Omega,
Lambda, Sigma 96 and lota 2)
Incorrect
quantity
starter cultures: Too little
with
will allow microbiological
solution
Chloride for
Cheese production
Maintain the temperature at
of 35⁰C.
7 as starter culture along Calcium
thermophilus it is between
growth as acidity will not St.Paulin
2) Ensure correct amount is added.
develop soon enough; high amounts will result in hard, dry, acidic cheese.
Physical: None Chemical:
Improper PRP: Proper Sanitation
cleaning
of
stirrer
may
pitchers
and
lead
to
contamination of milk and starter cultures Ripening (2 hours)
Biological: Improper action Maintain temperature of milk
of starter cultures on milk in the range of 35 ⁰C to 40⁰C due to inefficient temperature which
may
microbiological
allow growth
as
time progresses. Physical:
Occurrence
foreign bodies
of Close
the
lid
pasteurization tank.
Chemical: None
34
of
the
Addition
of
Rennet
pasteurized milk.
toBiological:
1)
Incorrect
quantity of rennet added:
1) 25 ml of rennet per litre of milk.
Low quantities will result in high cheese
moisture which
content will
in
allow
microbiological growth. High quantities will result in the curd becoming very dry. Biological: 2) A high pH
2) pH of 4.6 is required for
may
casein to precipitate.
allow
pathogens
to
recontaminate pasteurized
the
milk
and
the
casein may not precipitate. Physical: None Chemical: None
Removal of whey, addition Biological: of water and cutting
Improper PRP:
Proper
personal
and
handling.
handling practices leads to
hygiene
contamination.
Sanitize the cutters arms and hands.
Physical: None Chemical:
Improper PRP: Proper sanitization of
sanitization of cutting tools
cutting tools.
leads to contamination Moulding
Biological:
Microbiological PRP: Sanitize the moulding
contamination may occur if container and cloth. the cloth and container used for moulding is not washed
35
properly. Physical: None Chemical: None Biological: None
Pressing
Physical: None Chemical: None
Removing
cheese
fromBiological:
moulds
Microbiological PRP: GHP and GMP.
contamination of cheese due to unhygienic practices Physical: None Chemical: None
Addition of salt (300 g/l of Biological: Microbial growth Add 300g of salt per litre of water) + water into buckets
due to improper dilution of water. The temperature of salt and water; inappropriate
water should be at 15 ⁰C
temperature of water. Physical: None Chemical: Unclean buckets
may
be
a
source
PRP: Proper Sanitation
of
contamination. Salting (Placing the buckets
Biological:
with the cheese in ageing
growth due to inappropriate
at 16-18⁰C for 10 hours in
cellar)
temperatures.
the ageing cellar
Microbiological Storage of cheese in buckets
Physical: None Chemical: None
36
Maturation
Biological:
Microbiological Salting of cheese & proper
contamination
(yeasts
and
setting of storage conditions
molds) of cheese due to
(14⁰C
improper storage conditions
prevent spoilage.
for
1
month)
to
and undesirable pH which may lead to its spoilage.
pH 4.1 to 4.6 is required to control
the
growth
microorganisms in cheese. Physical: None Chemical: None
37
of
Risk Assessment for determined hazards (Chart 3) Processing Step
Hazards
Risk Assessment
Raw Milk Receival
S
F
S*F
2
2
III.
Physical: Presence of foreign bodies
1
2
III.
Chemical: Presence of antibiotics will inhibit
2
1
III.
3
1
III.
Biological: Milk is stored in tanks that, if 2
1
II.
Biological: Bacteriological contamination can
occur if the buckets containing milk are unclean.
the growth of starter cultures making the curd soft and floppy. Raw Milk Storage
Biological: Improper temperature and time
controls can lead to vegetative pathogens and spoilage microorganisms multiplying to levels that may be capable of overwhelming the pasteurization process
unclean, can result in bacterial contamination. Physical: None
0
0
Chemical: Traces of cleaning and disinfecting
1
1
0
0
0
Physical: None
0
0
0
Chemical: Traces of cleaning and disinfecting
1
1
0 I.
substances Passage of milk through the Biological: None heat exchanger
chemicals
38
I.
Pasteurization
Biological:
Pathogenic
( Bacillus Yersinia
cereus,
microorganisms 3
Listeria
enterocolitica,
1
III.
0
monocytogens ,
Salmonella
spp.,
Escherichia coli O157:H7, Campylobacter jejuni)
may
survive
due
to
improper
pasteurization temperature and control.
Physical: None
0
0
Chemical: Traces of cleaning and disinfecting
1
1
I.
Biological: 1) Starter cultures may act slowly 3
1
III.
3
1
III.
Physical: None
0
0
0
Chemical: Improper cleaning of pitchers and
1
1
chemicals in pasteurization tank. Stirring Addition of Omega and Sigma 41 starter cultures along with Calcium Chloride Solution for Tomme Cheese production
due to low temperature of milk which results in microbiological contamination as time progresses and too high a temperature for milk may inactivate the starter culture.
Addition of Omega, Lambda, Sigma 96 and lota 7 as starter
Biological: 2) Incorrect quantity of starter
culture along with Calcium cultures: Too little will allow microbiological Chloride solution for St.Paulin
growth as acidity will not develop soon
Cheese production
enough; high amounts will result in hard, dry, acidic cheese.
stirrer may lead to contamination of milk and starter cultures
39
I.
Biological: Improper action of starter cultures
Ripening (2 hours)
3
1
III.
Physical: Occurrence of foreign bodies
2
1
II.
Chemical: None
0
0
0
3
1
III.
3
1
III.
Physical: None
0
0
0
Chemical: None
0
0
0
2
1
Physical: None
0
0
Chemical: Improper sanitization of cutting
2
1
II.
contamination 2
1
II.
on milk due to inefficient temperature which may allow microbiological growth as time progresses.
Addition
of
pasteurized milk.
Rennet
toBiological: 1) Incorrect quantity of rennet added: Low quantities will result in high moisture content in cheese which will allow microbiological growth. High quantities will result in the curd becoming very dry.
Biological: 2) A high pH may allow pathogens
to recontaminate the pasteurized milk and the casein may not precipitate.
Removal of whey, addition of Biological: Improper handling practices leads water and cutting
II.
to contamination. 0
tools leads to contamination Moulding
Biological:
Microbiological
may occur if the cloth and container used for moulding is not sterilized properly. 40
Pressing
Removing cheese from moulds
Physical: None
0
0
0
Chemical: None
0
0
0
Biological: None
0
0
0
Physical: None
0
0
0
Chemical: None
0
0
0
Biological: Microbiological contamination of 3
1
III.
cheese due to unhygienic practices Physical: None
0
0
0
Chemical: None
0
0
0
2
1
Physical: None
0
0
Chemical: Unclean buckets may be a source
2
1
II.
3
1
III.
Physical: None
0
0
0
Chemical: None
0
0
0
contamination 3
1
III.
0
0
Addition of salt (300 g/l of Biological: Microbial growth due to improper water) + water into buckets
II.
dilution of salt and water; inappropriate temperature of water. 0
of contamination. Salting (Placing the buckets
Biological: Microbiological growth due to
with the cheese in ageing
inappropriate temperatures.
cellar)
Maturation
Biological:
Microbiological
(yeasts and molds) of cheese due to improper storage conditions and undesirable pH which may lead to its spoilage. Physical: None
41
0
Chemical: None
HACCP Decision tree utilized to determine the critical control points (Diagram 2) 42
0
0
0
Critical Control Point determination using the decision tree (Chart 4) Processing Step
Hazards
Q1
Q2
Q3
Q4
Conclusion
(Y/N)
(Y/N)
(Y/N)
(Y/N)
(CCP
or
not)
Raw
Receival
Yes
No
Yes
Yes
Not a CCP
of Yes
No
No
-
Not a CCP
of Yes
No
No
-
Not a CCP
No
Yes
Yes
Not a CCP
No
Yes
Yes
Not a CCP
Biological: Milk
Bacteriological contamination can occur if the buckets containing milk are unclean. Physical:
Presence
foreign bodies Chemical:
Presence
antibiotics will inhibit the growth of starter cultures making the curd soft and floppy.
Raw Storage
Biological: Milk
Improper Yes
temperature controls
and
can
lead
time to
vegetative pathogens and spoilage microorganisms multiplying to levels that may
be
capable
overwhelming
of the
pasteurization process Biological: Milk is stored Yes
43
in tanks that, if unclean, can result in bacterial contamination. Chemical:
Traces
of Yes
No
No
-
Not a CCP
-
-
-
-
-
-
-
-
-
-
No
No
-
Not a CCP
Yes
-
-
CCP
-
-
-
-
No
No
-
Not a CCP
cleaning and disinfecting materials Passage of milk Biological: None through the heat Exchanger
Physical: None Chemical:
Traces
of Yes
cleaning and disinfecting chemicals
Biological:
Pathogenic
Yes
microorganisms ( Bacillus cereus,
Listeria
monocytogens
,
Yersinia
enterocolitica, Salmonella
spp.,
Escherichia
coli
O157:H7, Campylobacter jejuni) may survive due to
improper
pasteurization
temperature and control.
Physical: None Chemical:
Traces
of Yes
cleaning and disinfecting chemicals
in
pasteurization tank. 44
Biological:
Stirring
Addition Omega
and
Sigma 41 starter
1)
Starter Yes
No
No
-
Not a CCP
No
No
-
Not a CCP
No
No
-
Not a CCP
No
Yes
Yes
Not a CCP
cultures may act slowly of due to low temperature of milk
which
results
in
microbiological cultures along contamination as time with Calcium progresses and too high a Chloride temperature for milk may Solution for inactivate the starter Tomme Cheese culture. production
Addition
of
Omega, Lambda, Biological: 2) Incorrect Yes Sigma
96
and quantity
lota 7 as starter
culture with
Calcium
for
starter
cultures: Too little will
along allow
Chloride solution
of
microbiological
growth as acidity will not develop
soon
enough;
St.Paulin high amounts will result
Cheese
in
production
cheese.
hard,
dry,
Chemical:
acidic
Improper Yes
cleaning of pitchers and stirrer
may
lead
to
contamination of milk and starter cultures
Ripening
hours)
Biological: (2
Improper Yes
action of starter cultures on milk due to inefficient temperature which may 45
allow
microbiological
growth
as
time
progresses. Physical: Occurrence of Yes
No
No
-
Not a CCP
foreign bodies Chemical: None
-
-
-
-
-
Yes
No
No
-
Not a CCP
Yes
Yes
-
-
CCP
Physical: None
-
-
-
-
-
Chemical: None
-
-
-
-
-
No
No
-
Not a CCP
Addition
Biological: 1) Incorrect of
Rennet
quantity to of rennet added:
pasteurized milk.
Low quantities will result in high moisture content in
cheese
allow
which
will
microbiological
growth. High quantities will result in the curd becoming very dry. Biological: A high pH
may allow pathogens to recontaminate
the
pasteurized milk and the casein
may
not
precipitate.
Removal of whey,
Biological:
Improper Yes
addition of water handling practices leads to and cutting
contamination.
46
Physical: None
-
-
-
-
-
No
No
-
Not a CCP
Yes
No
No
-
Not a CCP
Physical: None
-
-
-
-
-
Chemical: None
-
-
-
-
-
Biological: None
-
-
-
-
-
Physical: None
-
-
-
-
-
Chemical: None
-
-
-
-
-
Removing cheese Biological: None
-
-
-
-
-
No
No
-
Not a CCP
-
-
-
-
Yes
-
-
CCP
Chemical:
Improper Yes
sanitization tools
of
cutting
leads
to
contamination Biological:
Moulding
Microbiological contamination may occur if the cloth and container used for moulding is not sterilized properly.
Pressing
from moulds
Physical: Contamination Yes
of
cheese
due
to
unhygienic practices Chemical: None
Addition of salt Biological:
Microbial Yes
(300 g/l of water)
growth due to improper
+
dilution of salt and water;
water
buckets
into
-
inappropriate temperature of water.
47
Physical: None
-
-
-
-
No
No
-
Not a CCP
Yes
No
Yes
Yes
Not a CCP
Physical: None
-
-
-
-
-
Chemical: None
-
-
-
-
-
Biological:
Yes
Yes
-
-
CCP
Physical: None
-
-
-
-
-
Chemical: None
-
-
-
-
-
Chemical:
Unclean Yes
buckets may be a source of contamination. Salting
(Placing
Biological:
the buckets with Microbiological
the
cheese
ageing cellar)
Maturation
indue
to
growth
inappropriate
temperatures.
Microbiological contamination (yeasts and molds) of cheese due to improper
storage
conditions undesirable
and pH
which
may lead to its spoilage.
48
Chart displaying the critical limits for each CCP (Refer Annex, Chart 5) HAZARD
Pathogenic
Bacteria
(Non
CCP
CRITICAL LIMIT
Pasteurization (CCP-1 B)
Pasteurize milk at 72⁰C for
Sporulating) Microbiological
1minute. (+/- 2⁰C) Monitoring of pH (CCP-2 B)
The pH should be at 4.6 (+/-
Contamination of pasteurized
2) for the casein to precipitate
milk
and
during the action of
to
prevent
microbial
rennet on milk
growth.
Microbiological growth due to Proper dilution of salt and
300g of salt per litre of water,
improper dilution of salt and
water;
monitoring
the temperature of water should
water during salting.
temperature of water (CCP-3 be at 15⁰C (+/- 2⁰C) B)
Microbial contamination due Monitoring of temperature and
Store at 14⁰C for 1 month,
to inappropriate temperature pH. (CCP-4 B)
pH 4.1 to 4.6 is required.
and pH during maturation
49
Chart displaying monitoring procedures to control critical limits during process (Chart 6) CCP
Pasteurization (CCP-1 B)
HAZARDS
PREVENTIVE MEASURES Pathogenic Pasteurize milk Bacteria (Non at 72⁰C for 1 Sporulating) minute to destroy the pathogens and control the temperature by using a glass thermometer. Ensure equipment is adequately maintained, correctly calibrated and serviced every 3 months.
Monitoring of Microbiological pH (CCP-2 B) Contamination of pasteurized milk during the action of rennet on milk
pH of 4.6 is required to prevent microbial contamination and for the casein to precipitate.
Proper dilution of salt and water; monitoring
Add 300g of salt per litre of water. The temperature of water should be
Microbiological growth due to improper dilution of salt and water
50
CRITICAL MONITORING LIMITS PROCEDURES Pasteurize Who? User milk at 72⁰C for 1minute. (+/- 2⁰C)
How?
Check with another thermometer
When?
During production
The pH Who? User should be at 4.6 (+/- 2) for the How? casein to Check the pH of precipitate whey with a pH and to meter. prevent When? microbial Before the curd is growth. cut. Who? Person incharge. 300g of salt per litre of How? water, Microbiological temperature analysis of water
the temperature of water(CCP-3 B)
during salting.
at 15⁰C
of water When? Once in a year (or should be at during uncertainty) (+/15⁰C 2⁰C)
Monitoring of temperature and pH. (CCP-4 B)
Microbial contamination due to inappropriate temperature and pH during maturation
Salting of cheese & proper setting of storage conditions (14⁰C for 1 month) to prevent spoilage. pH 4.1 to 4.6 is required to control the growth of microorganisms in cheese.
Store 14⁰C for month, pH 4.1 4.6 required.
51
at Who? The producer 1 to is How?
With thermometer pH meter.
the and
When?
Every two weeks.
6. BIBLIOGRAPHY
http://www.codexalimentarius.net/search/advancedsearch.do (RECOMMENDED INTERNATIONAL CODE OF PRACTICE, GENERAL PRINCIPLES OF FOOD HYGIENE, CAC/RCP 1-1969, Rev. 4-2003)
http://www.geladairy.com/DAIRYMAGH.htm (Spoilage and Pathogenic Microorganisms in Milk)
http://www.raw-milk-facts.com/Raw_Milk_FAQ.html (How long can raw milk keep?)
http://www.renconz.com/renco_Rennet.cfm (Action of rennet in cheese making)
http://www.ces.ncsu.edu/depts/foodsci/ext/pubs/antibioticresidues.html (Preventing antibiotic residues in milk)
http://www.cfsan.fda.gov/~ear/daihaz.html (Hazards and Controls Guide For Dairy Foods HACCP, Guidance for Processors, Version 1.1 June 16, 2006)
http://www.pubmedcentral.nih.gov/articlerender.fcgi?artid=535134 (Milk Contamination and Resistance to Processing Conditions Determine the Fate of Lactococcus lactis Bacteriophages in Dairies)
http://www.specialistcheesemakers.co.uk/best_practice/Cheesemaking.htm (The Specialist Cheesemakers Code of Best Practice, Identifying hazards in the processing chain)
http://www.microbeworld.org/news/water_quality/news_water_quality_01.aspx (Microbiological contaminants in water)
52