HACCP Plan-Dairy Plant ISA

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

0



1



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.

3

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

5

\ 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.

7

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)

8

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

9

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.

10

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.

11

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.

12

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)

17



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.

18

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

21



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.

22

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


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


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.


PRP: Qualified supplier.

Chemical: Presence of antibiotics will

PRP: Supplier should adhere to

inhibit the growth of starter cultures

good herd practices.


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


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.


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.


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.


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


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


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.


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


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


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


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.


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


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


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

HACCP Plan-Dairy Plant ISA

Recommend Documents