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Disclaimer All information contained in this booklet has been obtained from sources believed to be accurate by Confederation of Indian Industry (CII). While reasonable care has been taken in its preparation, CII makes no representation, express or implied, as to the accuracy of the information. All information should be considered solely as statements of opinion. For further information please refer/browse the references/documents mentioned. Copyright (C) Confederation of Indian Industry 2009
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Website: www.cii-iq.in
Foreword
CII Institute of Quality (CII-IQ) has the unique distinction of being one of the first institutions in India to provide pioneering, value added services to enhance competitiveness of Indian Industry. Commencing operations in 1999, it has impacted participants from manufacturing, services, education and governance sectors through its awareness campaigns, training and consultancy services. Since 2002, its Food Safety and Quality (FSQ) initiative, in collaboration with national bodies and knowledge partners of international repute, continues to provide customized consultancy services to upgrade food-factories to international food safety requirements. Combined with timely training, updates on emerging international standards, quality tools & techniques, organizational excellence models, national standards formulation, research & publications it strives to make India a Safe Food Destination and the Food factory of the World. India is one of the largest producers of Milk, a product which provides nourishment for the human body in more than one way. It contains in abundance high quality nutrients such as protein, vitamin D, calcium and a well known anticancer micronutrient called selenium. Hence, it is essential that one consumes Safe & Hygienic processed milk and thus prevent food borne illness. This specific booklet, FAQs on Food Safety and Quality Milk & Milk Products is designed at disseminating basic knowledge on how to produce and handle milk hygienically by adopting food safety practices and shall serve as a handy ready-reckoner for Milk handlers in the Milk Supply Chain and the Consumer. The aim of this booklet, therefore, is to help acquire basic knowledge in following areas by listing some useful Frequently asked Questions (FAQs) on Food Safety & Quality concerns of the complete milk supply chain. It addresses the following: How to produce clean milk that is fit for human consumption How to handle milk in accordance with good hygienic practices Basic Quality tests, Benefits, Emerging concerns and New research findings on Milk & Milk Products CII-IQ will gladly welcome suggestions for improvements to this booklet.
CII-IQ, Bangalore
July, 2009
Uttam Chatterjee
Expert Group on Food Safety & Quality Cll Institute of Quality
Chairman
CII Institute of Quality Expert Group on Food Safety and Quality: 2009-2010
Chairman - Expert Group on Food Safety & Quality & Regional Director - Quality - Asia Region, Hindustan Unilever Ltd
Mr Uttam Chatterjee
Mr M N Lari
Director, Hind Agro Industries Ltd Divisional Chief Executive, ITC Ltd Managing Director, Tasty Dairy Specialities Ltd Head - Knowledge Management & Food Safety, JohnsonDiversey Ltd.
Director, Allanasons Ltd Head - Quality, Bharti Del Monte India Pvt Ltd
Dr K N Shashikanth
Ms Suneeti Toteja
Mr M N Rao
Mr Sunil Apte
Mr Azizullah Khan
Dr Prema Viswanath
Mr Himanshu Gupta
Director - Quality Operations, Coca Cola India CEO, Consumer Coordination Council
Mr Anil Jauhri
Asst. Director, Quality Council of India General Manager QAD Nirulas Corner House Pvt Ltd
Mr Harsharan Marwah
Mr Rajiv Malik
Dr Ramanand Shukla
Mr B P S Puri
Mr Sanjay Chaudhary
WHO Consultant
Mr V K Chopra
Mr P Dasgupta
Mr Naresh Goyal
Mr Indranil Chatterjee
CONTENTS
Sources & Supply of Milk Purchasing Dairy Products Handling & Storage after Purchase Processing Packaging Storage & Shelf life Categories Consumption Criteria Quality Characteristics Health Benefits & Nutritional Characteristics Food Safety & Spoilage Regulation Emerging Concerns New Research Findings References 1 5 6 8 10 11 13 15 18 23 28 33 34 35
Is it necessary to purchase milk from reliable suppliers? M ILK S OURcES & S UPPLY
OF
Milk should be purchased from reliable suppliers so that you are assured of the quality of milk.
very quickly. To ensure that raw milk remains fresh for a longer time, one need to practise good hygiene during milking and when handling the milk afterwards.
What are the Important factors that influence milk quality at source? Feeding
A well-fed and watered animal will produce high quantities of milk of good composition. If cows are fed a diet that is low in forages and high in starch, the butterfat content may fall below 2.5%. Thus, a good balance of forage and concentrates is important. One may give the cow feed supplements but be sure to observe proper proportions. It is advisable not to feed the cow with silage during milking or shortly before milking, as this will give rise to off-flavours in the milk. It is recommended that silage feed be provided two hours before milking.
Zoonoses
Zoonotic diseases like tuberculosis and brucellosis can be spread to humans through milk. Cows suffering from such diseases should be referred to a qualified veterinary practitioner who will decide on the fate of the animal. Farmers are encouraged to vaccinate their animals against brucellosis. Animals should also be checked periodically for all types of contagious diseases and treated promptly in case of infections.
Mastitis
Mastitis is an inflammation of the mammary glands in the udder caused by infection with disease-causing bacteria. These bacteria can also end up in the milk and result in illness if the milk is consumed. For this reason, milk from cows suffering from mastitis should not be sold or drunk. One can control mastitis by observing general hygiene and proper milking procedures. Hair at the udder should be kept short by trimming. Cows suffering from mastitis should be treated by a qualified veterinary practitioner. Milk from animals that are undergoing antibiotic treatment should not be consumed or sold until the withdrawal period has elapsed because antibiotic residues may cause allergies and drug resistance in consumers.
OF
M ILK
Wash hands with soap and clean water before milking. Wash the udder with a clean cloth and warm water. Dry the udder with a clean dry cloth. Make the first draw into a strip cup to check for mastitis and throw away from the milking area even if the milk appears clean. Use clean containers for milking. Cows with mastitis should be milked last and their milk discarded. Milk from cows under antibiotic treatment should not be sold or consumed until 3 days after last treatment or as advised by the veterinary practitioner. After every milking, dip the teats into an antiseptic dip. During milking, the milker should not: (a) have long nails, (b) sneeze, spit or cough, (c) smoke. Release the cow from the milking area as soon as milking is finished. After milking, sieve the milk through a strainer or muslin cloth to remove solid particles that may have fallen in during milking. Cover the milk to avoid contamination. Move the milk to a clean and cool area.
What are the types of containers to be used for milk handling and storage?
Always use certified foodgrade containers for milking, e.g. aluminium, stainless steel or foodgrade plastic jerry cans designed for single use only. Metal containers are preferable because these are easy to clean and
sterilize. Do not store milk in plastic jerry cans that previously contained paint, herbicides and other chemicals because traces of these substances can taint milk.
There are various types of cleaning and sanitation agents that have been specially designed to clean and disinfect milk-handling equipment. One may also use foodgrade liquid soap, which is a good cleaning agent that also destroys bacteria. Always rinse equipment properly after cleaning to prevent detergent residues contaminating the milk. Cleaning agents should be stored properly and handled with care because some of them may be corrosive to the skin. Always follow the manufacturers instructions for proper use of detergents.
AFTER PURcHASE
PROcESSING
How milk is processed at Dairy plants ?
Milk processing involves: 1. 2. 3. 4. 5. Cooling of milk 4-6 C. Clarification of milk to remove dust , dirt particles. Pasteurization of milk to destroy disease causing bacteria. Homogenization of milk to distribute fat evenly. Standardization of milk composition to conform to the legal and consumer requirement. 6. Packaging of milk in pouches, tetra pack and bottles.
What are the Post Pasteurization requirements for ice cream, cheese and other such milk products?
Good manufacturing practices must be followed in post pasteurization to ensure no contamination. Post pasteurization ingredients are need to be inspected prior to addition, addition procedures, measuring containers etc are need to cleaned and sanitized for manufacturing of milk products.
Ice cream - Air Supply to Freezer requires that area around air intake to freezer is clean and sanitary. Cheese Acid development must occur at a rate established for each type of cheese. All re-useable containers must be clean and sanitized.
P ROcESSING
PAcKAGING
Is it required to label all dairy products containers being sold?
Yes, all containers must be labelled . Foodborne illness outbreaks associated with milk or milk products occur every year. This is why properly labelled milk intended for human consumption is a requirement for any sale. Additional labelling requirements include name and location of business, contact information, pull dates, product identity (use common name), and volume. Perishable packaged food products with a projected shelf life must state the pull date on the package label.
What are the recommended storage guidelines and shelf life of Milk and Milk Products?
Product wise Recommended Storage details:
Milk & Milk Products How to Store CAN KEEP IT APPROXIMATELY THIS LONG On Refrigerator shelves 35-40F (2-4C) Refrigerate imPasteurized Fresh Whole or mediately in original Skimmed Milk, Sweet Cream, container. Keep Flavored Milk Drinks container closed. Sweetened & condensed milk Keep covered. (opened) In Freezer 0F (-18C) stored in MVP* materials
1 week 3 months, in aerosol can3 days, prepared from mix 2 weeks, bought frozen (once thawed) 7-10 days 2 weeks
Do not freeze.
Whipped topping
Keep covered.
Do not freeze.
Do not freeze. Butter made from pasteurized cream - 3 to 4 months. Do not freeze others.
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S TORAGE &
SHELF LIFE
Do not freeze. Unopened cartons for (Change of texture, 30 days. Opened for 1 body appearance. week. Check code date. Separation of fat emulsion.)
How to Store
CAN KEEP IT APPROXIMATELY THIS LONG On Refrigerator shelves 35-40F (2-4C) In Freezer 0F (-18C) stored in MVP* materials
Cool cooked dishes quickly and refrigerSoft custards, Milk Puddings, ate within 2 hours. Cream and Custard Fillings Refrigerate cold for Cakes and Pies dishes immediately after preparation.
5-6 days
Do not freeze.
Ice Cream
Store in original container in freezer Do not store here. or transfer to a MVP container. Refrigerate in original package and over wrap tightly in 1 month. If mold aluminum foil, plastic forms, cut off. wrap or plastic bag tightly closed to avoid drying. 1 week
2-3 weeks
Natural Hard Cheese and Semi-Hard Cheese and Processed (Cheddar, Swiss, Parmesan, Brick, Bleu, etc.)
Freezing affects texture**. Still suitable for cooking. Thaw in refrigerator. Do not freeze soft cheeses. Do not freeze (Can freeze cream cheese***. Texture may change.) Do not freeze. Do not freeze.
Soft Cheese (cream, cottage, Refrigerate tightly limburger**,camembert**) covered. Cheese Spreads Evaporated Milk (opened) Refrigerate tightly covered. Refrigerate tightly covered.
1 month 1 week
Keep containers Homogenized, reconstituted tightly closed. Don't 1 week dry nonfat and skimmed return unused milk to original containers.
Do not freeze
CATEGORIES
What is UHT milk ?
UHT means Ultra High Temperature pasteurization: Milk is heated to 135-150 C for 1-2 seconds. The flavour, taste and nutritive value of milk remain unchanged and the microbes present are made inactive. The process keeps the milk safe in aseptic packaging without refrigeration for 120 days.
What is Whey?
Whey is a co-product of cheese processing. Milk had undergone a coagulation process through which the casein proteins and milk fat were removed as cheese curd. Sweet whey is the co-product of rennet coagulated cheese such as chedder and swiss. Whereas acid whey is the co-product of acid coagulated fresh chesse, principally cottage cheese. Whey is a natural milk derived ingredient which provided one of the highest protein efficiency ratios of any protein.
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C ATEGORIES
It is similar to ricotta cheese, but lower in moisture and made from whole milk instead of whey. There are three types of khoya batti, chickna, and daan-e-daar. Batti, meaning rock, has 50% moisture by weight and is the hardest of the three types; it can be grated like cheese. It can be aged for up to a year, during which it develops a unique aroma and a mouldy outer surface. Chickna (slippery or squishy) khoya has 80% moisture. For daan-e-daar, the milk is coagulated with an acid during the simmering and has moderate moisture content. Different Khoa is used for different preparation. A concentration of milk to one-fifth volume is normal in the production of khoa. Khoa is used as the base for a wide variety of Indian sweets. About 600,000 metric tons is produced annually in India. Khoa is made from both cow and buffalo milk.
CONSUmPTION cRITERIA
Is raw milk safe for consumption?
Raw milk is not safe for consumption. Milk, in its natural state, contains numerous microorganisms including pathogen, even dust, dung, foreign particles can fall into raw milk. Processing of raw milk removes dust and dirt particles invisible to the naked eye and reduces about 90% of spoilage bacteria population, thus making processed packed milk safe for consumption.
How to Store and Handle milk & milk products for safe consumption?
Milk is perishable. To ensure its safety and quality: Refrigerate milk at 40 F or less as soon as possible after purchase and store in the original container. Return milk to the refrigerator immediately after pouring out the amount needed. Never return unused milk to the original container. Keep milk containers closed to prevent the absorption of other flavors. An absorbed flavour changes the taste, but the milk is still safe. Protect milk from exposure to strong light since light can reduce its riboflavin content and cause off-flavors. Refrigerate dairy products immediately once you arrive home. Store dairy products like milk, cream and cottage cheese in their original containers. Always close lids tightly. Keep milk and dairy foods refrigerated at 45 F or less. Store milk in the coldest part of the refrigerator. Avoid storage in door panels.
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C ONSUmPTION
cRITERIA
Avoid exposing milk, cream and other products to bright light. Light can affect the flavor of milk. When cooking with milk, do not leave the milk sitting on the counter for a prolonged period of time. Ice cream should be stored in a freezer at 0 F or less. Do not let ice cream melt and then refreeze.
Health (NIH), American Dietetic Association (ADA) and regulatory agencies in 30 countries.
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C ONSUmPTION
cRITERIA
QUALITY CHARAcTERISTIcS
What type of Adulerants should be tested in milk?
Each area has specific adulterants prevalent which should be identified by gathering data/intelligence from the milk area. Common adulterants are sugar, salt, urea, water (& pond water), mineral and vegetable oils, maltodextrins and neutralisers etc.`
What are the basic milk quality test at collection point of milk?
There are four basic milk quality tests: Sight-and-smell (organoleptic) test. Clot-on-boiling test. Alcohol test. Lactometer test. These tests are routinely carried out at milk collection points to ensure that only milk of acceptable quality is received.
Procedure
Open a can of milk. Immediately smell the milk and establish the nature and intensity of smell, if any. The milk will not be accepted if it smells slightly sour or has foreign odours like paint or paraffin.
Observe the colour of milk. Deviation from the normal yellowishwhite colour indicates damage to the udder (reddishblood, or yellowpus). Check for any foreign bodies or physical dirt, which may indicate that the milking and handling were not done hygienically. Touch the milk container to feel whether it is warm or cold. This indicates elapsed time since milking (if not chilled thereafter) and will influence the lactometer test for adulteration.
Judgement
Abnormal appearance and smell that may cause milk to be rejected could be due to: Type of feed or atmospheric taint. Cows in late lactation. Bacterial taints. Chemical taints or discolouring.
Milk previously chilled and subjected to excessive shaking during transportation. Adulteration with other solids (may also show as sediments or particles). Boiling, if milk fat is hardened.
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Q UALITY C HARAcTERISTIcS
used to measure milk density is called a lactometer. Most lactometers are usually marked from 0 (representing density of 1.000 g/ml) to 40 (representing density of 1.040 g/ml).
Procedure
Leave the milk to cool at room temperature for at least 30 minutes and ensure its temperature is about 20C. Stir the milk sample and pour it gently into a 200 ml measuring cylinder or any container deeper than the length of the lactometer. Let the lactometer sink slowly into the milk. Take the lactometer reading just above the surface of the milk. If the temperature of the milk is different from the lactometer calibration temperature (20C), then use this correction factor: For each C above the calibration temperature, add 0.2 lactometer degrees (L) to the observed lactometer reading. For each C below calibration temperature, subtract 0.2 lactometer degrees (L) from the observed lactometer reading. Note: These calculations are done on the lactometer readings (e.g. 29 instead of the true density of 1.029 g/ml).
Judgement
If the milk is normal, its lactometer reading will be between 26 and 32. If the lactometer reading is below 26 or above 32, the milk will be rejected because it means that it has been adulterated with added water or solids.
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Q UALITY C HARAcTERISTIcS
Low acidity indicates chemical adulteration by soap or cleaner. Ideally milk with Total acidity in the range of 0.14 0.17 or pH:6.6 -6.8 are accepted.
What are the other critical things need be monitored while receiving milk?
Measure temperature of milk and test milk for presence of antibiotics. At temperatures >4C, pathogen growth is accelerated. Pasteurization may not destroy all pathogens in highly contaminated milk and is unable to destroy certain toxins of microbial origin. Consumption of milk products containing antibiotics can, in certain cases, produce severe allergic reactions that could result in death.
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of concerns that these products will lead to weight gain. Together milk, cheese and yogurt provide a unique nutrient package of nine essential nutrients that help people improve overall diet quality.
How can someone with lactose intolerance still enjoy dairy foods?
Lactose intolerance does not mean dairy intolerance. In fact, research shows that most people who are lactose intolerant can enjoy up to two cups of milk a day, particularly if they drink it with meals. Other tips for reducing symptoms include eating aged cheeses that are naturally low in lactose and drinking lactose-free milk.
The ability to digest lactose differs among different human races. This defect is commonly noticed among Asian races. As an individual grows old, the beta galactosidase secretion decreases. It is related to the genetics of the individual. Temporary lactose intolerance is sometimes noticed among children who have been suffering from intestinal disorders and nutritional deficiency diseases.
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What is Probiotic?
Pro means for and bio means life. Hence, probiotics are generally considered as agents which favour the well being of a human being or an animal by various mechanisms. Probiotics are generally lactic acid producing live bacteria which, when ingested orally, brings out the desirable effect in the individual by getting implanted in the intestinal tract. The mechanism of action include competitive replacement of the pathogens from the intestinal tract, production of metabolic compounds inimical to the growth of pathogens etc. Generally lactobacilli, especially, Lactobacillus acidophilus is considered as a good probiotic. Pro-biotic ice cream and curd sold in the market has added live micro organisms .
How many servings of dairy foods should one eat every day?
No matter what is age, dairys nutrients are an essential part of promoting good bone health and good overall health. The Dietary Guidelines for Americans recommends 3 servings of lowfat or nonfat milk and dairy products every day as part of a healthy diet.
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temperatures reduce the rate of growth of the spoilage bacteria. If you do not have a refrigerator or cooler, you can store milk in a cold-water bath or wrap the milk can with a wet sack or blanket, but ensure that the milk container is well covered to prevent dirt from entering the milk.
Why does milk curdle when heated after standing at room temperature for considerable period of time?
Milk contains a variety of microorganisms which are capable of converting lactose present in the milk to lactic acid, increasing the acidity. When the milk is stored at room temperature (30-37 C) for considerable period of time, it provides ideal temperature for the growth of most of the spoilage causing organisms(Streptococcus lactis), and in turn increases the acidity. When the acidity increases beyond 0.20% lactic acid, the milk clots on boiling or heating.
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ropiness throughout the milk may be caused by Enterobacter aerogens, Streptococcus lactis. Adequate pasteurization of milk readily destroys most of these kinds of bacteria.
What are the microbiological hazards that may occur in Paneer or Chhana?
Paneer or Chhana is an unaged, acid-set, non-melting farmer cheese made by curdling heated milk with lemon juice or other food acid. Chhana is the most popular base material of some of the Indian dairy products like sandesh, rosogolla, chum-chum, pantoa, chhana-kheer, chahna-murki, jalbhara etc. Panner or Chhana having high moisture content is prone to microbiological contamination. The most common types of mould contamination reported in chhana are penicilium, aspergillus, mucor, rhizophus, fusarium and paecilomyces.
Soy milk is considered as one of the Food allergen as declared by Codex Authority.
What are the tests for evolution of effectiveness of Cleaning and Sanitation in Dairy Industry?
The effectiveness of cleaning and sanitation determines the number and type of microrganism entering into the dairy product to be processed. The cleanliness and hygienic condition of the equipment can be accessed by:
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Visual inspection for presence of milky water,sedimentation of milk product, dust, redues etc. Laboratory tests that can be applied includes: a) Swab method to measure actual number of microorganism, which remains to large and small areas on flat or curved surfaces. b) Rinse method is used for bottles, cans and utensils, which could be closed for rinsing. It provides information on the bacteriological condition of bottle or cans immediately after washing. c) Contact agar colony count method can be used for large number of tests, in a short period of time. d) Product Quality measure method in this method, product which passes through the equipment is measured for its bacteriological quality and specially for changes in quality. e) Chlorine strength test In this method, efficiency sterilization of equipment is done on the basis of available chlorine.
What are the critical control points for Finished Product storage of Dairy Products?
Three critical control points are required to be monitored for Finished product storage: Storage temperature: Finshed product storage areas need to be maintained below maximum allowable temperatures: a) Ice Cream: < -18C b) Butter, cultured products, fluid: 4C c) Cheese - soft: 4C - hard: > 4C during aging process. Multiple Use of Finished Product Storage Area needs to be verified that any potential contaminants are stored separately from finished products. Returned Products Isolation procedures must ensure returned product cannot be resold or reused.
REGULATION
Is there any enacted Food Law or Order to regulate Milk and Milk Products in India?
Milk and Milk Products Order, 1992 (MMPO) is administered by the Department of Animal Husbandry & Dairying ,under the Ministry of Agriculture, Government of India for regulating the production, supply and distribution of milk and milk products .
Is it necessary to obtain registration/permission from concerned Government Authority to set up dairy business/plant?
As per Milk and Milk Products order, 1992 , no person or manufacturer shall set up a new plant or expand the capacity of the existing plant without obtaining registration/permission from registered authority . For this purpose , such person may make an application in the form specified in the first schedule along with the prescribed fees to the registered authority for obtaining registration certificate.
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R EGULATION
EmERGING cONcERNS
What are the pesticides contamination that occur in milk?
Organochlorine pesticides, first among the xenobiotics, are lipophilic in nature and have, therefore, tendency to accumulate in the fatty matter. The presence of these residues in milk is not unexpected since milk contains fat as one of the principal constituents.Pesticides occur in milk because of excretion from lactating mammary glands getting their supply from blood which in turn may get contaminated through various routes. Intentional or unintentional contamination of the cow may arise from the efforts for control of parasites on the animal,insect control in stables, environment(water, air and soil), fodder.
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N EW R ESEARcH
FINdINGS
by Michael Zemel from the University of Tennessee found that the recommended levels of dairy products may be used during weight maintenance without contributing to weight gain compared to diets low in dairy products. The study adds to the ongoing debate about a potential role of milk and other dairy foods in weight management. Zemel and his co-workers recruited 244 overweight and obese people with an average age of 40.3, and randomly assigned them to a weight loss and subsequent weight management regime of either the recommended daily intake of three dairy servings as fluid milk, yogurt, or cheese, or to consume one or fewer servings of dairy per day. During the weight management part of the study, the researchers failed to observe any significant differences between the groups in terms of weight or body composition. On the other hand, the recommended dairy group consumed significantly more energy than the low dairy group. A reduction in blood calcitriol (1,25-dihydroxyvitamin D) levels, a form of vitamin D in the body, was observed in the recommended. Calcitrol may modulate both lipogenesis and lipolysis, said the researchers, which both result in increased lipid filling and adiposity (fat buildup).
References
Selected web references
www.idfdairynutrion.org www.idfa.org www.cfsan.fda.gov www.hewittsdairy.com www.french-cheese.com www.indairyasso.org www.michigan.gov/mda www.oznet.ksu.edu www.state.pa.us www.moomilk.com www.nationaldairycouncil.org http://agr.wa.gov www.betterhealth.vic.gov.an www.milkmagic.com http://en.allexports.com www.dairyforall.com www.microbiologyprocedure.com www.codexalimentarius.net www.fao.org www.hkmj.org
Hygienic milk Production Module1- Kenya Dairy Board Milk Processing guide series Vol 4 FAO/TCP/KEN/6611 Project Guidelines for the Application of a HACCP Program in a dairy plant BC Centre for Disease Control Dairy council Digest March/April 2002 The Technology of Traditional milk Products in developing CountriesFAO corporate document Nutrition & Metabolism 2008,5:28 Food Microbiology Fourth Edition by W.C. Frarier and D.C. Westhoff.
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