Yogurt HACCP Plan

The Food Safety Plan – H.A.C.C.P

Terms of reference: This linear HACCP plan covers the manufacture of an apple yogurt product, packaged in a pot. It will start at raw materials intake through to dispatch of processing plant. The HACCP plan will cover final product safety and will look at the following hazards: Physical

Glass and hard brittle plastic Metal

Chemical

Pesticide residues in fruit Chemical residues associated with the packaging materials Chemical residues associated with cleaning

Biological

Unwanted bacteria yogurt, raw milk and fruit.

The company has in place a number of effective prerequisite programs including: 

Cleaning and Sanitising



Pest Control



Personal Hygiene Requirements



Staff Training

The company complies with the following acts of legislation 

Regulation (EC) No 178/2002 of the European Parliament and of the Council



Regulation (EC) No 852/2004 of the European Parliament and of the Council

And the following codes of practice/guidelines documents were used in developing this HACCP plan: 

Campden BRI HACCP: A Practical Guide (Fourth edition). Guideline No 42



British Retail Consortium Global Standard for Food Safety (Issue 6)



Department of Health Guidelines for the Safe Production of Heat Preserved Foods



Institute of Food Science and Technology Food & Drink Good Manufacturing Practice, A Guide to its Responsible Management.



Codex Alimentarius Food Hygien Basic Texts (Third Edition)

1.1 The HACCP food safety team 1.1.1 The HACCP plan is developed and managed by Fab Foods’ multi-disciplinary food safety team which includes those responsible for quality/technical, production operations, engineering and other relevant functions. The team leader has an in-depth knowledge of HACCP and is able to demonstrate competence and experience. The team members have specific knowledge of HACCP and relevant knowledge of product, process and associated hazards. In the event of the company not having appropriate in-house knowledge, external expertise will used, but day-to-day management of the food safety system remains the responsibility of the company. HACCP Team Member Quality Assurance

Responsibility Carries out systematic measurements, comparison with BRC standard, monitoring of processes and an aims to prevent error. Quality Control Reviews the quality of all factors involved in production with focus on process outputs. Production Specialist contribute details of what actually happens on the production line throughout all shift patterns Engineer Provides information on the operating characteristics of the process equipment under study and the hygienic design of equipment and buildings Microbiologist Understands the microbiological hazards and risks associated with the product. Others Including; specialist equipment operators, hygiene manager, ingredient and packaging buyers, distribution manager, maintenance and calibration operators. External HACCP Members If knowledge is not available in-company, consultation with an eternal resource will be carried out. Table 1: Breakdown of Fab Food’s HACCP Team and Responsibilities.



All persons are trained in HACCP and repeat the training annually.

Below is a table showing how Fab Foods operates an organised structure of the HACCP team.

Table 2: Fab Foods operation of an organised structure of the HACCP team.

1.2 Prerequisite programmes 1.2.1 Fab Foods has established and maintains environmental and operational programmes necessary to keep an environment suitable to produce safe and legal food products Prerequisite programmes include: 

Cleaning and Sanitising



Pest Control



Personal Hygiene Requirements



Staff Training

Process Step

Hazard

Prevention

Control Limits

Monitor Method

Monitor Frequency

Record Sheet

Person Responsi ble

Corrective action

Validation

ENVIRONMENTAL HYGIENE

Environ mental Hygiene

Presence of listeria/ Salmonell a

Environm ent swabs

Listeria/sa lmonella absent

ISO approved methods

Weekly monthly/ Quarterly

Pathogen file

QC Manager

HYGIENIC HANDLING OF INGREDIENTS * Milk, * Starter Cultures (S.thermo SOP philus& Presence Testing L.burglari of procedure Pathogen ous) pathogeni Below for screening * Fruit c Pathogen QC pathogen investigati monitorin (diced microorga screening Weekly Manager limits on of g sheet apples) nisms pathogens *Stabiliser (pectin) * Flavour Enhancers CLEANING, MAINTENANCE & PERSONNEL HYGIENE AT PRIMARY PRODUCTION Cleaning, Maintena nce & Personnel Hygiene at Primary Productio n

Physical /Micro contamina tion

Cleaning procedure s

Clean areas, swab enterobact eria <10

Hygiene inspection , swabs

Weekly

Hygiene records Cleaning records Maintenan ce records

Technical Manager

Full investigati on, re clean and re swab area

In case of pathogen presence immediate rejection of product.

Areas not cleaned correctly, revisit areas with operator, reclean and reswab

Weekly review of pathogen file by QC

Presence of pathogeni c microorga nisms

Weekly review of hygiene cleaning and maintenan ce

LOCATION

Location of Factory

Cross contamina tion

Productio n area segregated

Segregate d area

Visual

NA

NA

Technical

Productio n areas must be segregated , if this is violated, investigat e reason

Internal and external audits

PREMISES Design, layout, Physical Internal /Micro Structure contamina s& tion Fittings EQUIPMENT Food Control & Monitori ng Equipme nt


Containe Physical rs For /Micro Waste & contamina Inedible tion Substanc es FACILITIES

Water Storage

Personal Hygiene/c aptive clothing

Legionella contamina tion


Food grade walls and equipment

Audit/Vis ual Inspection

Clean colour coded waste containers

Legionella testing

Hand washing/c aptive clothing

Temperat ure monitorin g CLEANING MANAGEMENT Temperat ure Control

Cleaning Program mes

Cleaning Program mes

Product contamina tion

Contamin ation due to ineffective hygiene procedure

Contamin ation due to ineffective hygiene procedure

Spray with acidic solution after clean on filler inside surfaces

CIP and hand cleaning procedure s

Clean & undamage d

Visual and Hygiene and housekeep ing audits

Clean & undamage d


Correct colour, clean and undamage d


Absent

Correct hand washing procedure s and change of clothing in productio n areas Temperat ure specificati ons

Ongoing.

Ongoing.

Clean daily

Monitorin g log created.

Daily monitorin g of waste containers

Legionella file

Ongoing/qua rterly

Hygiene records

All Employee s

Report deviations to supervisor /manager

Action log

As per schedules

Temperat ure Records

QC manager

Report deviations to QC manager

Weekly audit of temperatu re records

Calibrated thermome ters

Visual inspection s, sanitizer checks and swabbing regimes

Productio n


Quality Control Officer

Visual hand swabs, and Hygiene and housekeep ing audits

Cleaning carried out to correct time, temperatu re and sanitizer strength

Hygiene and Housekee ping Audits

QC manager

Hygiene and household records created. Continuou s monitorin g.


Water storage records

All areas at least twice annually

Surface hygiene tests


Technical

Action log created. Actions monitored continuou sly

Investigat e if legionella found in water, risk access product

External company sample and test

Surface hygiene tests


After each cleaning cycle

As per cleaning scheduled/ frequencie s

Cleaning logs

Cleaning logs

Productio n operators

Operators/ Team leaders/Te chnical

Do not proceed with productio n until satisfactor y hygiene has been achieved Do not proceed with productio n until satisfactor y plant hygiene has been achieved.

Weekly review of cleaning logs. Internal/e xternal audits Weekly review of cleaning logs. Internal/e xternal audits

PEST CONTROL SYSTEMS

Pest Control

Microbiol ogical, Physical or chemical risks associated with pests.

Pestguard Plus contract in place with Rentokil

All evidence of pest activity reported and controlled.

Pest Control Technicia n

Pest control technician -monthly visits

Rentokil File reports.

Technical Manager

All pest control actions & corrective actions taken reported to technical manager.

Rentokil report.

WASTE MANAGEMENT

Waste Managem ent

Rubbish provides environme nt for pest harborage.

Rubbish cleared on a regular and routine basis.

PERSONAL CLEANLINESS Fully document ed Hygiene Code of Practice compiled from NonHygiene Customer complianc Policy Codes of e with Practice general and Good hygiene Manufact practises uring Practices.

All rubbish to be removed.

100% complianc e by all site personnel.

Hygiene & Housekee ping Audit schedule in place.

Hygiene & Housekee ping Audit schedule in place.

Personnel hand swabbing regime in place for productio n area.

Visitors

Visitors not aware of the site hygiene requireme nts. Unfit/unw ell visitors enter site.

Rules for Visitors Procedure in place. Sign in at reception. Sign in agreement to follow company rules while on site.

No unfit visitors allowed in high risk areas of factory.

Hygiene rules

Table 3: Fab Foods Prerequisite Process.

Once per month

Quarterly

Monthly

Each visitor.

Waste transportat ion document ation Any reports of visual sightings of waste/deb ris in the productio n area or surroundi ng areas.

Hygiene records

Hygiene records

Visitors Book

Waste coordinati ng officer

Technical Manager

Technical manager

Reception ist

Action log created and issued to Technical Manager

Action log created and issued to General Manager

Re swab and if positive discuss hygiene policy with the operator

Vistors must meet the correct safety citeria to be allowed access to the premise

Waste document ation file.

Hygiene and Housekee ping audit

Hygiene and Housekee ping audit

Annual audit of visitor records

 Cleaning and Sanitising

The order of operation for cleaning/sanitizing of food product contact surfaces is 

Rinse



Clean



Rinse



Sanitize.

The company uses a number of types of cleaning.

Mechanical Cleaning. Often referred to as clean-in-place (CIP). Requires no disassembly or partial disassembly. Clean-out-of-Place (COP). Can be partially disassembled and cleaned in specialized COP pressure tanks. Manual Cleaning. Requires total disassembly for cleaning and inspection.

Following cleaning, sanitization is completed, types include; Thermal Sanitization involving the use of hot water or steam for a specified temperature and contact time. Chemical Sanitization involving the use of an approved chemical sanitizer at a specified concentration and contact time.

Cleaning and Sanitization is carried out to remove unwanted matter on food-contact surface, referred to as Food Soil. Detergents and cleaning compounds are composed of mixtures of ingredients that interact with soils in several ways: Physically active ingredients alter physical characteristics such as solubility or colloidal stability. Chemically active ingredients modify soil components to make them more soluble and, thus, easier to remove. Example of cleaning agents used are Alkaline Builders, Acid Builders, Water Conditioners, Oxidizing Agents, and Enzyme-based detergents. The below table is used when selecting cleaning agent to use.

Surface Deposit

Cleaning Solubility

Sugar

Water soluble

Fat

Alkali soluble

Protein

Alkali soluble

Starch

Water soluble, Alkali soluble

Monovalent Salts

Water soluble; Acid soluble

Table 4: Surface Deposit vs. the Cleaning Solubility

Examples of sanitizers include; Chlorine, Iodophors, Quarternary ammonium compounds, Acid anionic, Fatty Acid, Peroxyacetic acid The below table can be used when selecting cleaning agent to use

Acid anionic

Fatty Acid

Peroxyacetic acid

Slightly corrosive Slightly irritating No

Slightly corrosive Not irritating

In most cases

Slightly corrosive Slightly irritating No

In some cases

Yes, below 3.0-3.5

Yes, below 3.54.0

Yes

Yes

Chlorine

Iodophors

Corrosive

Corrosive

Irritating to skin

Irritating

Effective at neutral pH Effective at acid pH

Yes

Slightly corrosive Not irritating Depends on type

Effective at alkaline pH Affected by organic material Affected by water hardness Residual antimicrobial activity Cost

Incompatibilities

Stability of use solution Maximum level permitted by FDA without rinse Water temperature sensitivity Foam level Phosphate Soil load tolerance

Yes, but unstable

Quarternary ammonium compounds Noncorrosive Not irritating

Yes

Yes, but less than at neutral pH Yes

No

In most cases

No

No

Less effective

Moderately

Moderately

Moderately

Partically

Partially

No

Slightly

Yes

Slightly

Slightly

Slightly

None

Moderate

Yes

Yes

Yes

None

Low Acid solutions, phenols, amines

High Highly alkaline detergents

Moderate Anionic wetting agents, soaps, and acids

Moderate Cationic surfactants and alkaline detergents

Moderate Cationic surfactants and alkaline detergents

Moderate Reducing agents, metal ions, strong alkalies

Dissipates rapidly

Dissipates slowly

Stable

Stable

Stable

Dissipates slowly

200ppm

25ppm

200ppm

Varied

Varied

100-200ppm

Moderate

None

None

High

Moderate

Moderate

None None None

Low High Low

Moderate None High

Low/Moderate High Low

Low Moderate Low

None None Low

Table 5: Comparison of the Chemical and Physical Properties in commonly used Sanitizers

It is important that the clean, sanitized equipment and surfaces drain dry and are stored dry so as to prevent bacteria growth. Necessary equipment must also be cleaned and stored in a clean, sanitary manner. Cleaning/sanitizing procedures are evaluated for adequacy through evaluation and inspection procedures. Adherence to prescribed written procedures (inspection, swab testing, direct observation of personnel) are continuously monitored, and records maintained to evaluate longterm compliance. (Schmidt, 2000) All areas regarding Cleaning and Sanitizing must be documented and signed in appropriate specification sheets.

 Pest Control Pest Control is carried out to eliminate the entry of insects and rodents into the food processing premises. Pests include: Rodents (Rats, Squirrels, Mice etc.) Cockroaches, Flies, Ant, Birds and other vertebrates. Control of Pests in done by an outside service provided by Rentokil. (Hazel House, Millennium Park, Naas, Co Kildare, 1890 333 888). Poisoned Bait, Traps, Electrical Discharge system, Repellents, Pitfall traps and Sticky insect traps are among the controls put in place by Rentokil. In addition to this: 

The exterior of the premises is well-maintained by designated maintenance staff, lawns are mowed once a week and any debris which could be a possible nesting place for rodents/insects are removed. Evidence of pests such as dropping are examined for.



The interior and exterior of processing plant is inspected twice weekly to ensure that no pests have begun to congregate.



Pest control is included on the factory daily schedule.



Drains onsite are fitted with rodent traps.



All entrances to the factory are effectively concealed from pests when closed.



In the event that a pest is found on the premises immediate action must be taken. Incident should be immediately reported to supervisor. Product recall may be necessary.



All areas regarding Pest Control must be documented and signed in appropriate specification sheets.

Personal Hygiene Requirements / Staff Training The below ‘house’ rules are in place as well and in conjunction with H.A.C.C.P. Staff are trained upon entry and annually by an official body which comply with the FSAI’s Guide to Food Safety Training Level 1 and Level 2. Prerequisite All staff in contact with food items must confirm they are free of disease before they are employed.

All staff in contact with food items must wear protective clothing.

Staff are prohibited staff who are experiencing vomiting or diarrhoea or have infected wounds on their hands or lower arms from handling unpackaged food items.

Ensure that staff put on disposable hair nets, and beard nets (where applicable) before putting on their protective clothing.

Control Measure Require new staff members to complete a questionnaire about their medical situation and/or arrange for them to be tested for infectious diseases. Clean white cotton/polyester overalls or coats for all staff in contact with unpackaged food are provided and dry cleaned. If a person has these symptoms either send them home until they are better or move them to an area when they do not handle unpackaged food items. Provide adhesive medical dressings for staff to put over any wounds, cuts or abrasions on hands or lower arms It is company policy to arrange for staff to be inducted and trained to do this.

Glove sizes are available to take into account the different sized hands/ The gloves should be tight fitting but not so tight Use gloves that are fit for purpose. as to be uncomfortable. Disposable gloves have are designed for use with food. For tasks such as cleaning or pest control use rubber, non-disposable, thick gloves. The facility is designed so staff must outer Staff must remove protective clothing layer of protective clothing - prior to going before going to the toilet. to the toilet. This will include installing hooks on which to hang the clothes coming off. Provide facilities for staff to store outdoor Install lockable cabinets in the changing clothes and personal effects. facility. Staff must to wash hands regularly especially after bathroom, food or smoke Signs are placed in bathrooms and in breaks; after handling waste or uncooked entrances to the processing areas food items and after sneezing or touching reminding people to wash their hands their faces. It is policy that eating, drinking or chewing Eating, drinking or chewing of gum in food of gum in food processing areas is processing areas is prohibited. prohibited. A canteen is provided for such activities.

Staff are trained to turn away and sneeze into the crook of their arm or into hands Staff should not sneeze over food items. over their face. Afterwards they should blow their nose with tissues & wash their hands All staff must sign a declaration saying they Wearing of any jewellery in food will abide by this policy. processing areas is prohibited. This Visitors are asked to remove jewellery. includes watches, ring, earrings, necklaces Signs to doorways leading into processing bracelets and hairpieces. areas remind people they should remove jewellery. Table 6: Personal Hygiene Requirements / Staff Training & Control Measures.

1.3 Description of the product 1.3.1 The scope of each HACCP plan, includes the products and processes covered, including 

Composition, e.g. raw materials, ingredients, allergens, recipe



Origin of ingredients



Physical or chemical properties that impact food safety, e.g. pH, aw



Treatment and processing, e.g. cooking, cooling



Packaging system, e.g. modified atmosphere, vacuum



Storage and distribution conditions, e.g. chilled, ambient



Target safe shelf life under prescribed storage and usage conditions



Instructions for use, and potential for known customer misuse, e.g. storage, preparation.

Process/Product type: Product name: Composition: Important product characteristics How it is to be used: Packaging: Shelf life: Where it will be sold: Labelling instructions: Special storage and distribution control: Table 7: Product Description

Yogurt Absolutely Apple Skim milk, skim milk powder, apple fruit, preservatives, bacterial cultures ( aw, pH, preservatives, processing Direct consumption Plastic cup and foil – sealed 2 weeks Retailers Within legal limits, as per BRC standards. Refrigerated at < 5°C

1.3.2 Fab Foods ensures that the HACCP plan is based on comprehensive information sources, which are referenced and available on request. It uses: 

the latest scientific literatures



historical & known hazards associated with specific food products relevant codes of practice



recognized guidelines



food safety legislation relevant for the production and sale of products



customer requirements.

1.4 Identified intended use 1.4.1 The intended use of the product by the customer is described, defining the consume target groups, including the suitability of the product for vulnerable groups of the population (e.g. infants, elderly, allergy sufferers).

1.5 Construction a process flow diagram 1.5.1 The prepared flow diagram covers each product, product category or process. This sets out all aspects of the food process operation within the HACCP scope, from raw material receipt through to processing, storage and distribution. It contains the following: 

plan of premises and equipment layout



raw materials including introduction of utilities & other contact materials, e.g water, packaging



sequence and interaction of all process steps



outsourced processes and subcontracted work



process parameters



potential for process delay



rework and recycling

 

low/high-care/high-risk area segregation finished products, intermediate/semi-processed products, by-products and waste.

1.Organic Milk Storage Silo 6,7,8 3b Incoming Packaging/ingredients

4. Filtration

2. Mixing Hopper

3. Addition of dry Ingredients (SMP, NaC) from ambient storage

Packaging in warehouse

5. Pumping of milk through balance tank Waste Milk to Effluent

6a. Preheating of Milk in Pasteuriser

6b. Homogenisation Path of Milk 6c. De-aeration 6d.Pasteurisation 93˚ C x 4min

CCP 1 Divert of Product where applicable

7. Inoculation - addition of Cultures from freezer

8. Incubation 36°-43°C

9. Cutting of yogurt ph 4.6

10.Filtration 0.5mm

11. Cooled 25° -30°C

13. Fruit addition from ambient storage

14. Addition & mixing of fruit of & yogurt in 12. Holding yogurt

holding tanks

15a. Lid & pot deboxing 16.Filling, sealing & dating of yogurt pots

15b.Pot & lid packaging

Waste yog to effluent plant & packaging to recycling/skip

17. Metal Detection

18. Blast Chilled

20.Trayed/palletised

19. Sleeves & trays packaging

Unit Operations 

Milk storage Silo

When the milk is received after passing quality testing. The milk is pumped from the tanker to the milk storage silos. Here the milk should be stored at <7˚C and held for no longer than 72 hours. Silos are agitated to make sure that the entire volume remains cold and that the milk fat does not separate from the milk. When the silo is empty, it is Cleaned In place with specific agents before the next milk from tankers are received. 

Mixing Hopper

Milk from the silo is then passed in to the mixing hopper, where ingredients which were stored at ambient temperature, such as calcium and vitamins are added to the milk to be enriched. It provides gentle agitated to distribute the ingredients to form a precise liquid. It provides cooling so the milk stays under 7˚C. 

Filtration

The type of filtration technology used in the industry is Microfiltration which is a low pressuredriven membrane filtration process, which is based on a membrane with an open structure allowing dissolved components to pass while most non-dissolved components are rejected by the membrane. In the dairy industry, microfiltration here which is used for bacteria reduction and fat removal in milk and whey as well as for protein and casein standardisation. The size of the membrane is 1.4µm. This is an essential process step to protect flavour, ensure nutritional value, and prevent microbial or physical contamination. It allows a product to have a specified fat content and for total fat and solids content. The type of membrane used in this filtration system is ceramic. They are resistant to temperature, chemicals and are easy to clean. 

Balance tank

The milk is then pumped in to a balance tank or float tank. The tank is equipped with a float valve. The purpose of this is to keep the milk at a constant level and to maintain a constant supply of milk to the regeneration section of the pasteuriser.



Pasteurisation

Milk which is still at 4˚C is pumped from the balance tank into the regeneration section of the plate heat exchanger, where it is heated. The plate heat exchanger contains a series of stainless steel plates stacked together with spaces in between them. The spaces are the forming chambers which hold the milk as it passes through. The milk will increase from 4˚C to 72˚C for effective pasteurisation. This is held for 15 seconds and then chilled again to 4˚C.

In the regeneration section the heat of the pasteurised milk is used to warm up the cold milk. Therefore the outgoing hot milk is the heating medium for the cold raw milk. The cold milk is the cooling medium for the hot milk, as it is used to cool down the hot milk from 72˚C to 4˚C. This all takes place in the plate heat exchanger where counter current flow is the most effective way of heat exchange. When the cold milk meets the oncoming hot milk, and is heated up, it is then passed through the holding tube which is long enough to last at least 15 seconds. Here the milk is being pasteurised. It flows to the regeneration section where it warms up the cool milk coming in and then off to the cooling section which is the final section.

The divert valve on the processing unit is used for diversion of any liquid that may be under the pasteurisation temperature. In this case if it’s under 72˚C the milk is brought back to the regeneration section and pasteurised again.

Pasteurisation is a thermal processing technique whereby milk is exposed to a time / temperature combination of 72˚C for 15 seconds. This will make the product safe for human consumption. Pasteurisation does not affect chemical, physical or organoleptic characteristics of the milk. The primary function of pasteurisation is a food safety function. However, as well as destroying pathogenic bacteria, pasteurisation will also destroy spoilage bacteria and denature enzymes. This has the effect of extending the shelf-life of milk, both chemically and microbiologically. Therefore pasteurisation is a critical control point in the process.

A Phosphastase test must be carried out to show pasteurisation was effective.(<350mU/L = Pass) All tests are recorded.

Raw milk contains acid and alkaline phosphatases. These enzymes catalyse the hydrolysis of certain phosphate esters. The thermal stability of alkaline phosphatase (AP) in milk is slightly higher than that of Microbacterium tuberculosis. AP is inactivated by heating milk to 72C and holding for 15seconds.

Inactivation of AP ensures the destruction of Microbacterium

tuberculosis. Adequately pasteurised milk will be phosphate negative. 

Homogenisation

Homogenisation process allows two immiscible liquids to become mixed. This is achieved by turning one of the liquids into a state consisting of extremely small particles distributed uniformly throughout the other liquid. When the milk is fed through the homogeniser, the workhead generates high shear rates. The milk is forced through a small passage at high velocity. The disruption of the fat globules is due to turbulence and cavitation. While milk is forced through, the large fat globules are broken down into smaller ones. Resulting in a size of 2-5 microns. This results in a stable emulsion, better mouth feel of the product, reduced sensitivity to lipid oxidation. 

Deaeration

Deaeration is the removal of oxygen and other dissolved gassed in the product. This is to prevent/avoid undesirable changes in the final end product. Not only free air can be removed but also mechanical air. Deaeration of a product can result in an oxygen level of <1ppm. This improves product quality and shelf life. 

Inoculation of culture starters

After deaeration of the milk, the temperature is maintained, The milk here is getting ready for yogurt production. This heat treatment is to denature about 80% of the whey proteins, particularly β-lactoglobulin, which in turn reacts with the κ casein to form a more stable micelle, and, to produce yoghurt with increased body and viscosity the starter cultures with are used are, Lactobacillus bulgaricus and Streptococcus thermophiles. 

Incubation/holding tanks

The milk is held for the fermentation process to be carried out. This occurs at a temperature around 45˚C.



Cutting of yogurt pH

These bacteria form a symbiotic starter culture to ferment milk. By creating the starter culture it increases the production of lactic acid in the fermentation process.

Streptococcus thermophilus starts to grow first dropping the milks pH from 6.6 to 5.0, and produces carbon dioxide and lactic acid. These products stimulate Lactobacillus bulgaricus to grow and further drop the pH to 4.2. The sugar found in milk is lactose, when the starter culture is added to milk it breaks the lactose into glucose. After the sugar glucose is formed it. Then it is fermented into lactic acid by the microorganisms.

The lactic acid decreases the pH of the milk and causes the casein, protein found in milk, molecules to denature and stick together. The milk then curdles to produce yogurt 

Filtration

Filtration of yogurt can remove the excess whey from fermentation process and gasses which were produced form the starter cultures. This improves quality and shelf life of the product. Filtration membrane used in this process is 0.5mm. 

Yogurt Holding Tanks

After filtration the yogurt is cooled and then passed into yogurt holding tanks. The tanks here keep the yogurt at the right temperature under atmospheric pressure. The yogurt is gently agitated to keep the yogurt mixed with no whey separation and to keep a good consistency for the product. 

Metal Detection

Metal detection is a very important procedure in the manufacturing process. The yogurt is frequently checked using a pipeline metal detector prior to final processing and final packaging. The product is normally pumped through a non-metallic pipeline which passes through the detector. Removal of contaminated product is achieved through the use of automated reject valves which divert the product flow out of the process. Any high viscosity products that are being produced which have the potential to solidify in the pipeline, there are heated pipelines and valves are used, to limit pipe blockages. This will remove all contaminated substances from the product, resulting in a high quality and safe product.



Blast Chilling

Blast chillers/freezers rapidly chill foods from a temperature of 140˚C to 40˚C in less than two hours. As for yogurt, this will be even less. Blast chillers are ideal for chilling foods quickly that are made on a daily basis. Blast chillers and freezers have powerful fans that create a fast even air flow that is very cold. It uses a high-powered refrigeration system to blast the cold air laterally over the product at high speed, extracting heat at an optimum rate, whilst maintaining food quality. After the chill or freeze cycle is complete, the equipment switches into Hold mode to keep the food at the required temperature. 

Traying/Packaging

After the yogurt has been chilled, it is then ready to be put into yogurt pots. These are single yogurt pots chosen for this product. The machine used here is the Automatic Rotary Type Cup Filling & Sealing Machine SP-2502. Cups fall into the holders on the machine, there are two stacks of yogurt cups, were two falls each time into the individual holders. These are then passed along to the dust and blow suction system. This takes away any access particles away from the cup. It passes on to a UV sterilizer, this kills all microbes that may be present in the cups which could have got contaminated during storage. It provides a sterile environment for the yoghurt. It moves on to the piston filler where the cup fills up with the chilled yogurt from the blast chillier. The amount of yogurt is poured out is calibrated on the machine. The cups are ready to be sealed, they are flushed with nitrogen, and the oxygen is reduced so that a longer shelf life can be obtained from the product. The yogurt cup is then sealed, brought to the out feed system of the machine where a lever comes down and sucks the yogurt filled cups out on to the vender belt to the labelling machine. The yogurt cups pass though the labelling machine, where is puts on a sleeve around the yogurt cup, stating all the requirements, such as yogurt name and nutritional information. A label is also stuck on the lid of the yogurt stating the best before date. 

Cold storage/Dispatch

The yogurts are taken of the labelling line and are stored at 4˚C in trays/ boxes in cold storage rooms. These are now ready to be picked up by the truckers through dispatch. A physical test is done before any of the yogurts are dispatched. The Yogurt is now sold to consumers.

1.6 Verification of flow diagram 1.6.1 The HACCP food safety team verifies the accuracy of the flow diagrams by on-site audit and challenge at least annually. Daily and seasonal variations are considered and evaluated. Records of verified flow diagrams are maintained.

1.7 List all potential hazards associated with each process step, conduct a hazard analysis and consider any measures to control identified hazards 1.7.1 The HACCP food safety team identifies and records all the potential hazards that are reasonably expected to occur at each step in relation to product, process and facilities. This includes hazards present in raw materials, those introduced during the process or surviving the process steps, and allergen risks. It also takes account of the preceding and following steps in the process chain. Fab Foods uses Risk Analysis to establish Hazards and uses it in conjunction with Food Standards such as Food Safety Requirements, HACCP, Good Manufacturing & Hygiene Practices and Total Quality Management to put an effective Food Management programme in place.

Table 8: Risk Analysis in conjunction with Food Standards such as Food Safety Requirements, HACCP, Good Manufacturing & Hygiene Practices and Total Quality Management.

1.7.2 The HACCP food safety team conducts a hazard analysis to identify hazards which need to be prevented, eliminated or reduced to acceptable levels. Consideration are given to the following: 

likely occurrence of hazard



severity of the effects on consumer safety



vulnerability of those exposed



survival and multiplication of micro-organisms of specific concern to the product



presence or production of toxins, chemicals or foreign bodies



contamination of raw materials, intermediate/semi-processed or finished product.

Where elimination of the hazard is not practical, justification for acceptable levels of the hazard in the finished product shall be determined and documented. 1.7.3 The HACCP food safety team considers the control measures necessary to prevent or eliminate a food safety hazard or reduce it to an acceptable level. Where the control is achieved through existing prerequisite programmes, this is stated and the adequacy of the programme to control the hazard is validated. Step

Process step

Hazards

1(a)

Raw Milk (Receive Milk)

Presence of microorganisms

1(b)

Raw milk (Release tests)

Antibiotics

1(c)

1(d)

Raw milk (Cooling)

Raw milk (Silo relase)

Foreign material

Control measures Microbiologi cal analysis. Keep records for each tanker route Rosa test Kundrat test ATK test In-line filter. Inspect tanker before offloading. Quality of gaskets

Microbial

Temperature

Microbial

Temperature and time

Chemical risk

Cleaning

Critical limits

Monitoring

Bactoscan results

Raw milk procedure

Negative

Raw milk procedure

Reject milk Follow up

Raw milk procedure

Daily tanker inspections

Cold chain procedure

Maintenance of ice banks

No damage gaskets

Milk Cooled to < 3oC Milk to be kept at minimum of 3oC Within parameters

procedure

Cold chain procedure GMP

Corrective action Reject milk if not to microbiologic al limits

Maintenance of silos Quarterly check by supplier of chemicals

Cleaning

Within parameters

GMP SOCP

Quarterly check by supplier of chemicals

Cleaning

Within parameters

GMP SOCP


Temperatur e and time Wash not more than 24 h before

GMP WI GLP

Re-pasteurise

Visual on PC display

Wash

2(a)

Cream separation

Chemical risk

3(a)

Homogenisatio n

Chemical risk

4(a)

Pasteurisation

Microbial


Microbial

Cleaning

Microbial

Cleaning

Physical foreign material

Production and process control

Microbial

Cleaning

5

Pasteurisation (Transfer of milk to holding tank) Loading milk for mixing

6

Powder mixing

7

T105 to storage tank

4(b)

8

9

Pasteurisation and homogenisation process

Cooling down to maturation temperature and ferment addition

Microbial

Time and temperature

Wash not more than 24 h before Wash not more than 24 h before Wash not more than 24 h before Pasteurisati on Temperature

& time

Wash


Wash

Temperatur e and recorder and visual on PC display Temperatur e and recorder and visual on PC display

Empty pasteuriser and repeat washing and sanitisation Too high: can be cooled with ice water; too low; stop the process

Temperature

Microbial

Cleaning

Wash not more than 24 h before


Wash

Microbial

Cleaning

Wash 1 hour before


Wash

Microbial

Cleaning

Wash 24 h before


Wash

Microbial

Cleaning

Wash 24 h before

Visual on PC display Viscosity Coliform Count Pre-cool temperatur e

14

Storage

Microbial

Lab test

< 4ºC 24 h

15

Dispatch

Microbial

Temperature

< 4ºC

12


Temperature

13

11

Wash

Microbial

Maturation and breaking of curd Cooling down, smoothing with filter and transfer to storage tank Addition of sterile apple fruit pieces Packing

10


Wash Visual on PC display Visual on PC display

1.8 Determination of the critical control points (CCP) 1.8.1 For each hazard that requires control, control points are reviewed to identify those that are critical. CCPs are those control points which are required in order to prevent or eliminate a food safety hazard or reduce it to an acceptable level. If a hazard is identified at a step where control is necessary for safety but the control does not exist, the product or process shall be modified at that step, or at an earlier or later step, to provide a control measure. Fab Foods implements a system by which critical points can be identified. Table 9: Decision Tree used by company to establish Critical Control Points. Simplified Decision Tree

Would a loss of control at this point result in a realistic risk of illness or injury?

YES

NO

Q2. Is there a later step at which this hazard is or can be controlled? (Under your control)

NO

YES

CCP

Not CCP

Not CCP

Ref: Advi s ed by the Chartered Ins ti tute of Envi ronmental Heal th (C.I.E.H) U.K.

Results of Decision Tree for CCP Determination Step 1(a)

Process step Raw Milk (Receive Milk)

Hazards Presence of microorganisms

Control point

Microbial

Control measures Microbiological analysis. Keep records for each tanker route Rosa test Kundrat test ATK test In-line filter. Inspect tanker before offloading. Quality of gaskets Temperature

1(b)


Antibiotics

Microbial


CP

Chemical risk

Cleaning

Foreign material 1(c) 1(d)

Raw milk (Cooling) Raw milk (Silo relase)

CP

CCP CCP CP

GMP 2(a) 3(a) 4(a) 4(b)

5 6

Cream separation Homogenisatio n Pasteurisation

Chemical risk

Cleaning

GMP

Chemical risk

Cleaning

GMP

Microbial


CCP

Pasteurisation (Transfer of milk to holding tank) Loading milk for mixing Powder mixing

Microbial

Cleaning

GMP

Microbial

Cleaning

GMP

Physical foreign material Microbial


GMP

Cleaning

GMP

Microbial


CCP

Microbial

Temperature

CCP

Microbial

Cleaning

GMP

Microbial

Cleaning

GMP

Microbial

Cleaning

GMP

Microbial

Cleaning

GMP

13

T105 to storage tank Pasteurisation and homogenisation process Cooling down to maturation temperature and ferment addition Maturation and breaking of curd Cooling down, smoothing with filter and transfer to storage tank Addition of sterile apple fruit pieces Packing

14

Storage

Microbial

Lab test

CP

15

Dispatch

Microbial

Temperature

CP

7 8

9

10

11

12

Fab Foods recognises the below as Critical Control Points in the production of the product. 1. The presence of antibiotics, and foreign material in raw milk, 2. Effective pasteurisation and homogenisation, 3. Maintaining the correct fermentation Temperatures

1.9 Establishment critical limits for each CCP 1.9.1 For each CCP, the appropriate critical limits are defined in order to identify clearly whether the process is in or out of control. Critical limits include: 

measurable wherever possible, e.g. time, temperature, pH



supported by clear guidance or examples where measures are subjective, e.g. photographs.

1.9.2 The HACCP food safety team validate each CCP. Documented evidence show that the control measures selected and critical limits identified are capable of consistently controlling the hazard to the specified acceptable level.

1.10 Establishment of a monitoring system for each CCP 1.10.1 A monitoring procedure is established for each CCP to ensure compliance with critical limits. The monitoring system is able to detect loss of control of CCPs and wherever possible provides information in time for corrective action to be taken. Means of monitoring include: 

online measurement



offline measurement



continuous measurement, e.g. thermographs, pH meters etc.



where discontinuous measurement is used, the system ensures that the sample taken is representative of the batch of product.

1.10.2 Records associated with the monitoring of each CCP include the date, time and result of measurement and are signed by the person responsible for the monitoring and verified, as appropriate, by an authorised person. Where records are in electronic form there is evidence that records have been checked and verified.

1.11 Establishment a corrective action plan 1.11.1 The HACCP food safety team specifies and documents the corrective action to be taken when monitored results indicate a failure to meet a control limit, or when monitored results indicate a trend towards loss of control. This includes the action to be taken by nominated personnel with regard to any products that have been manufactured during the period when the process was out of control.

1.12 Establishment of verification procedures 1.12.1 Procedures of verification are established to confirm that the HACCP plan, including controls managed by prerequisite programmes, are effective. Examples of verification activities include: 

internal audits



review of records where acceptable limits have been exceeded



review of complaints by enforcement authorities or customers



review of incidents of product withdrawal or recall.

Results of verification are recorded and communicated to the HACCP food safety team.

Critical Control Points Management Critical Control Point (CCP)

Presence of Antibiotics in raw milk

Presence of foreign material in raw milk

HTST Pasteurisat ion

Maintainin g the correct Fermentati on Temp.

Significan t Hazard Allergic reactions to residues, Developm ent of resistant strains of bacteria, Removes starter cultures

Can cause physical, biological and/or chemical adverse effects.

If not carried out correctly, harmful spoilage m/org can grow

Microbial

Critical Limits for each preventat ive measure

See Table 11 Below

Foreign material must be absent in milk.

72°C for 20 seconds

TVC <1,000 cfu/ml on day 1; <5,000 cfu/ml on day 12

25 – 30 oC

Monitoring

What

Presence of antibiotic s Mainly BetaLactam

Presence of Foreign Matter

Temperat ure 0C Presence of cfus per ml of the sample

Temperat ure 0C

How

DSM DelvoTest & Charm Test

ISO 5538:200 4 Milk Inspectio n by attributes

Check & sign-off on continuou s chart recorder

Temperat ure and recorder and visual on PC display

Frequenc y On each batch of milk in all tankers, silos, cream vats, fermentati on tanks.

On each batch of milk in all tankers, silos, cream vats, fermentati on tanks.

Every 2 hours

Every 30 minutes

Who

Correcti ve actions

On site micro lab.

Reject & Dispose, inform Farm Liaison Officer and the Dep.t of Agricult ure

On site micro lab.

Remove or Reject & Dispose, inform Farm Liaison Officer and the Dep.t of Agricult ure

Pasteurize r Operator

Fermentat ion Superviso r

Records

Verificati on

Corrective action log. Antibiotic testing log. Milk & Yogurts quality log.

For each batch processed the QA superviso r will review each log

Corrective action log. Antibiotic testing log. Milk & Yogurts quality log.


Empty pasteuris er and repeat washing and sanitisati on

Corrective action log. Pasteurisat ion testing log. Milk & Yogurts quality log.


Too high: can be cooled with ice water; too low; stop the process

Corrective action log. Fermentati on testing log. Yogurt quality log.


Table 10: Critical Control Points Management including; Significant Hazard, Critical Limits, Monitoring, Corrective actions, Records, and Verification

Table 11: Comparison of the EU maximum residue limits (EEC Regulation 2377/90 and amendments) with the sensitivities of the microbial inhibition assays for the detection of antibiotics in milk.

1.13 HACCP Plan Overview Step

Process step

1(a)

Raw Milk (Receive Milk)

1(b)


Hazards

Presence of microorganisms

Antibiotics

1(c)

Raw milk (Cooling)

Foreign material

Microbial

Microbial 1(d)

Raw milk (Silo relase)

Chemical risk

2(a)

Cream separation

Chemical risk

3(a)

Homogenisatio n

4(a)

Pasteurisation

5

Pasteurisation (Transfer of milk to holding tank) Loading milk for mixing

6

Powder mixing

7

T105 to storage tank

4(b)

8

Pasteurisation and homogenisation process

Control measures Microbiologi cal analysis. Keep records for each tanker route Rosa test Kundrat test ATK test In-line filter. Inspect tanker before offloading. Quality of gaskets Temperature

Control

Critical limits

Monitoring

point

CP

Bactoscan results

Raw milk procedure

Reject milk if not to microbiologic al limits

CCP

Negative

Raw milk procedure

Reject milk Follow up

CCP

No damage gaskets

Raw milk procedure

Daily tanker inspections

Milk Cooled to < 3 oC

Cold chain procedure

Maintenance of ice banks

CP


CP

Cleaning

GMP

Milk to be kept at minimum of 3oC Within parameters

procedure s

Corrective action

Maintenance of silos Cold chain procedure GMP


Within parameters

GMP SOCP

Quarterly check by supplier of chemicals Quarterly check by supplier of chemicals

Cleaning

GMP

Chemical risk

Cleaning

GMP

Within parameters

GMP SOCP

Microbial


CCP

GMP WI GLP

Re-pasteurise

Microbial

Cleaning

GMP

Temperatur e and time Wash not more than 24 h before


Wash

Microbial

Cleaning

GMP

Physical foreign material


GMP

Microbial

Cleaning

GMP

Microbial


CCP

Wash not more than 24 h before Wash not more than 24 h before Wash not more than 24 h before Pasteurisati on Temperature

& time


Wash


Wash


Wash

Temperatur e& recorder & visual on PC display

Empty pasteuriser and repeat washing and sanitisation

9

Cooling down to maturation temperature and ferment addition

CCP

Temperature

Microbial

Cleaning

GMP

Wash not more than 24 h before


Microbial

Cleaning

GMP

Wash 1 hour before


Microbial

Cleaning

GMP

Wash 24 h before


Microbial

Cleaning

GMP

Wash 24 h before

Visual on PC display Viscosity Coliform Count Pre-cool temperatur e

14

Storage

Microbial

Lab test

CP

< 4ºC 24 h

15

Dispatch

Microbial

Temperature

CP

< 4ºC

12

Wash

Temperature

13

11

Too high: can be cooled with ice water; too low; stop the process

Microbial

Maturation and breaking of curd Cooling down, smoothing with filter and transfer to storage tank Addition of sterile apple fruit pieces Packing

10

Temperatur e and recorder and visual on PC display

Wash

Wash Wash Visual on PC display Visual on PC display

Table 12: HACCP Plan Overview (where CP = Control Point, CCP = Critical Control Point, GMP = Good Manufacturing Practice, SOCP = Standard Operating Cleaning Procedure)

1.14 HACCP documentation and record keeping 1.14.1 Documentation and record keeping are sufficient to enable the company to verify that the HACCP controls, including controls managed by prerequisite programmes, are in place and maintained.

Doc & Record 

Ingredients

Supplier certification documenting compliance with processor’s specifications along with Certificates of Analysis

 Processor audit records verifying supplier compliance 

Storage temperature records for all ingredients 

Product safety

Data and records to establish the efficacy of barriers in maintaining product safety

Data and records establishing the safe shelf life of the product, as age of product can affect safety

Processing

Records from all monitored CCP’s

Records verifying the continued adequacy of the process

Packaging

Records indicating compliance with specifications of packaging materials

Records indicating compliance with sealing specifications

Storage and distribution

Temperature records

Records showing that no product is shipped after shelf life date

Documentation of the adequacy of the processing procedures from a knowledgeable process authority

Storage temperature records for temperature sensitive ingredients

Table 13: Documentation and Record keeping of the HACCP standard.

Deviations and corrective actions Indicating approved revisions and changes in ingredients, formulations, processing, packaging and distribution control

Documents used to control HACCP:

Sample documents and records from I.S. 340:2007

1.15 Review of the HACCP plan 1.15.1 The HACCP food safety team reviews the HACCP plan and prerequisite programmes annually and prior to any changes which may affect product safety. Changes can include 

change in raw materials or supplier of raw materials



change in ingredients/recipe



change in processing conditions or equipment



change in packaging, storage or distribution conditions



change in consumer use



emergence of a new risk, for example adulteration of an ingredient



developments in scientific information associated with ingredients, process or product.

Appropriate changes resulting from the review shall be incorporated into the HACCP plan and/or prerequisite programmes, fully documented and validation recorded.

Yogurt HACCP Plan

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