GITHUNGURI DAIRY FARMERS CO-OPERATIVE SOCIETY LTD MILK PLANT

HACCP MANUAL

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Food Safety Policy.

Githunguri Dairy Farmers Co-Operative Society ltd (GDFCS) is committed to providing safe dairy
products to our consumers by ensuring that all stages of milk production, collection, processing,
storage and distribution conform to the highest food safety standards.

To achieve this, we shall:

Maintain suitable prerequisite programs throughout the value chain.

Continuously identify all potential food safety hazards in all processes and their effective
control measures.
Monitor and control the hazards as per the established HACCP principles in order to guarantee
products safety.

GDFCS shall establish and maintain appropriate programmes to ensure customer satisfaction First
Time All Times.

We shall endeavor to monitor and review the established food safety management system to
continuously conform to the requirements of ISO 22000:2005 standard.

We shall adhere to the set statutory and regulatory requirements.

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We shall ensure that the Food Safety Policy is understood, implemented and maintained at all levels
through use of effective and suitable internal and external communication channels.

Definitions

Food safety
Concept that food will not cause harm to consumers when prepared /eaten according to intended use.

Food chain
Sequence of the stages and operations involved in the production, processing, distribution, storage
and handling of a food from primary production to consumption.

Food safety hazard

Biological chemical or physical agent in food with a potential to cause adverse health effect.

Food safety policy

Overall intention and direction of an organization in regard to food safety as formally expressed by
top management.

End Product
Product that will not undergo any other processing/transformation by the organization.

Control Measure
Action or activities that can be used to prevent or eliminate a food safety hazard.
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Hazard analysis.
Systematic identification of hazards, assessment of risk associated with the hazards, establishment of
control measures and critical control points within a segment of food chain.

Pre-requisite programme (PRP)

Basic conditions and activities that are necessary to maintain a hygienic environment suitable for
production, handling and provision of safe food for consumption.

Operational Pre-requisite programme.(OPRP)

Conditions and activities that have been identified by hazard analysis as essential in order to control
hazard in the processing environment.

Critical Control Point

A stage/step at which control must be applied to prevent/eliminate food safety hazard/or reduce it to
acceptable level.
Monitoring
Conducting a planned sequence of observations to assess whether control measures are operating as
intended.

Correction
Action to eliminate a detected non conformity.
Corrective action
Action to eliminate the cause of a detected non conformity.
Verification.
Confirming through the provision of objective evidence that specified requirements have been meet.
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Validation
Obtaining evidence that the control measure are capable of being effective
HACCP plan
A document prepared in accordance to HACCP principle and aimed at ensuring the control of hazard
in the segment of the food chain under consideration.

7 PRINCIPLES OF HACCP SYSTEM.

1. Conduct a hazard analysis

2. Determine the critical control point (ccps)

3. Establish the critical limits.

4. Establish a system to monitor and control ccp

5. Establish the corrective action to take when monitoring indicates that a particular CCP not in
control.

6. Establish procedures for verification to confirm that the HACCP system is working effectively.

7. Establish documentation concerning all procedures and records appropriate to these principles
and the application.
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Logic sequence/ Flow

1. Assemble a Food Safety Team (HACCP TEAM)

2. Describe the products

3. Identify the intended use

Construct Flow Diagram

4.

On site Confirmation of the Flow Diagrams

5.

List all potential hazards

Conduct hazard analysis
Consider control measures
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Determine the CCPs

7.

Establish Critical limit for each CCP

8
Establish monitoring system for each CCP

9.

Establish Corrective Action

Establish verification procedure

10.

Establish documentation and record keeping.

11.

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Hazard associated with food

Food safety hazards fall into 3 main categories.

Physical hazards
Chemical hazards
Biological Hazards

1. Physical hazards/contaminants.

These are mainly associated with foreign matter. The foreign matter be may come with raw materials, packaging
materials, water be introduced during production from the environment or from food handlers.

Examples of physical contaminants from:

a) Raw Materials: sand,stones,soil,metal fillings/parts, plastic, glass fragments,wood,paint chipping, pins,

paper dust etc
b) Food handlers: Jewellery,hair,nails,cloth,nail varnish, gloves, buttons etc
c) Environment:Insect,hairs,dust,glass fragments sand,stones,soil,metal fillings/parts,
plastic,glass,wood,paint chipping, pins, paper etc

2. Chemical hazards/Contaminants.

These are introduced through raw material, water, surface contact, handling or added during preparations.
Chemical hazard cause long term health effect since they accumulate in the host body.

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Examples of chemical contaminants from:

a) Pestcides, herbcides, fertilizer.

b) Cleaning chemicals and disinfectant residues
c) Lubricants
d) Paint fumes/chippings
e) Unapproved food additives i.e. colourants,flavour,presevatives
f) Toxic metal eg tin, mercury, lead, arsenic etc.

3. Biological Hazards.

These are micro organism capable of causing illness when ingested with food. They are introduced in food
from raw materials, dirty equipments/packaging materials, pests, food handlers, waste and dust and aerial
contaminants. These pathogens fall into 3 categories.

a) Pathogenic bacteria eg Salmonella,Ecoli,shigella,staphylococcus

b) Pathogenic virus eg Avian flu virus,H1NI virus R.Valley fever,
c) Pathogenic yeast and moulds (produces toxin eg aflatoxin).

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PRELIMINARY TO HACCP ANALYSIS

Product name Fresha whole milk

Product Specifications Refer QA STD-02, KS 30:2002
Intended use Making beverage or direct Consumption
Type of Packaging Plastic Pouch, Tetra Classic carton, bottles
Storage condition Best stored under refrigeration
Shelf life 48hrs
Distribution requirement Cold chain.

Product name Fresha Lala

Product Specifications Refer QA STD-04: KS 05-491
Available flavours Natural.
Intended use Direct Consumption.
Type of Packaging Tetra Classic Carton, Plastic bottles, plastic
pouch
Storage condition Store under refrigeration
Shelf life 10 days
Distribution requirement Cold chain.

Product name Fresha Yoghurt.

Product Specifications Refer QA STD-03,KS 34:2001
Available types Flavoured, Natural and Real fruit.
Intended use Direct Consumption, as a desert./ for each
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product per brand
Group user who are vulner
Group of vulnerable Identify the
Un intended use (misuse of product) No repacking
Type of Packaging Plastic cups , Plastic bottles-sizes
Labelling Reference to particular label
Storage condition Store under refrigeration
Shelf life 14 days
Distribution requirement (Vehicles/distributors/direct sales/
Statutory/ Ks 34:2001

Product name Fresha Butter

Product Specifications Refer QA STD-05.KS-05-27:2000.
Intended use Confectionary Spreads, cooking fat.
Type of Packaging Bulk 10 kg,Plastic Containers,Wrappers
Storage condition Store under refrigeration
Shelf life 1 Year
Distribution requirement Cold chain.

Product name Fresha Superfine Ghee.

Product Specifications Refer QA STD-06: KS 1790:2003
Colour Golden
Intended use Cooking fat.
Type of Packaging Plastic Containers.
Storage condition Store at room temperature
Shelf life 1 Year
Distribution requirement Room temperature.

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KEY TO HAZARD ANALYSIS

(A) RISK = SEVERITY X PROBABILITY (Rated from 0.5 5)

Score < 5 Preventative control measures, but do not enter decision tree

Score 5 Preventative control measures and enter decision tree

(B) DECISION TREE (HAZARDS ASSESMENT TOOL)

QUESTION 1 (Q1): Do preventive control measures prevent, eliminate or reduce the hazard to an acceptable
level?
ANSWER: If Yes proceed to Q2, if No modify process (and make a new rating) or develop new preventative
control measure that does prevent, eliminate or reduce the hazard to an acceptable level.

QUESTION 2 (Q2): Are preventive control measures implemented?

ANSWER: If Yes proceed to Q3, if No implement preventative control measures.

QUESTION 3 (Q3): Will a subsequent process step eliminate or reduce hazard to an acceptable level?
ANSWER: If No proceed to Q4, if Yes NOT CRITICAL, SO PRE-REQUISITE PROGRAMME

QUESTION 4 (Q4): Can the hazard be monitored by objective, direct measurable parameters for controlling
all the products?
ANSWER: If Yes CCP (CRITICAL CONTROL POINT), if No O-PRP (EXTRA IMPORTANT GENERAL
MEASURE IN PRE-REQUISITE PROGRAMME)

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RAW MILK RECEPTION

STEP PROCESS HAZARDS RISK Q1 Q2 Q3 Q4 CLASSIFI CONTROL PLAN
STEP CATION
1 Grading Chemical antibiotics 33 = 9 YES YES NO NO OPRP -OPRP PLAN 1
- detergents residue 13 = 3 - - - -
- paraffin 11 = 1 - - - - -OPRP PLAN 2
- preservatives ( H202) 33 = 9 YES YES YES NO OPRP
- off flavours /odour 13 = 3 - - - -
Biological pathogens (B.arbotus, 53 = 15 YES YES YES - PRP Specific program
E.coli, L. monocytogenes, Y. (Extension Services)
enterocolitica, C.jejuni,
S.typhimurium,M.tuberculosis)
Physical cleaning fibers 13 = 3 - - - - PRP -Cleaning and
- hair/soil/sand/dung 13 = 3 - - - - Sanitation program
- glass fragments 13 = 3 - - - - -GMP
- additives 11 = 1 - - - -
(floor/margarine) 11 = 1 - - - -
- insects
2 Coarse Chemical detergents residue 13 = 3 - - - - PRP -Cleaning and
filtration Sanitation program

Biological yeast and moulds 51 = 5 YES YES YES - PRP -GMP

Physical fibers 13 = 3 - - - - PRP -Cleaning and

- sand/soil particles 13 = 3 - - - - Sanitation program

3 Pumping Physical metal parts 31 = 3 - - - - PRP Preventive

- seals/gaskets 13 = 3 - - - - Maintenance

4 Fine Chemical detergents residue 13 = 3 - - - - PRP -Cleaning and

filtration Sanitation program
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Physical dirt 13 = 3 - - - - PRP -Cleaning and

Sanitation program

Biological pathogens (B.arbotus, 53 = 15 YES YES NO NO OPRP OPRP PLAN 3

E.coli, L. monocytogenes, Y.
enterocolitica, C.jejuni,
S.typhimurium,M.tuberculosis)
5 Chilling Chemical ammonia 30.5 = 1.5 - - - - PRP -Preventive
- Freon 30.5 = 1.5 - - - - Maintenance
- glue 30.5 = 1.5 - - - -

Physical - gaskets 10.5 = 0.5 - - - - PRP -Preventive

Maintenance
Biological psychrophiles 50.5 = 2.5 - - - - PRP -Preventive
- yeast and mould 50.5 = 2.5 - - - - Maintenance
- aflatoxin 50.5 = 2.5 - - - -

6 Raw milk Chemical detergent residue 13 = 3 - - - - PRP -Cleaning and

storage - lubricants 10.5 = 0.5 - - - - Sanitation program
-Preventive
Maintenance
Biological pathogens (B.arbotus, 51 = 5 YES YES YES - PRP -Cleaning and
E.coli, L. monocytogenes, Y. Sanitation program
enterocolitica, C.jejuni, -Instrumentation
S.typhimurium,M.tuberculosis) -GMP

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RAW MILK PROCESSING

STEP PROCESS HAZARDS RISK Q1 Q2 Q3 Q4 CLASSIFI CONTROL PLAN

STEP CATION
1 Pumping Chemical detergent residue 13 = 3 - - - - PRP -Cleaning and
chilled water Sanitation program

Biological pathogens 51 = 5 YES YES YES - PRP -cleaning

(B.arbotus, E.coli, L.
monocytogenes, Y.
enterocolitica, C.jejuni,
S.typhimurium,M.tuberculosis)
Physical metal parts 31 = 3 - - - - PRP -Preventive
- seals/gaskets 13 = 3 - - - - Maintenance

2 Balance tank Chemical detergent residue 13 = 3 - - - - PRP -Cleaning and

Sanitation program

Physical dust 13 = 3 - - - - PRP -GMP

- level sensor 13 = 3 - - - - -Preventive
probes/wire 13 = 3 - - - - Maintenance
- insects
Biological pathogens 51 = 5 YES YES YES - PRP -Cleaning and
(B.arbotus, E.coli, L. Sanitation program
monocytogenes, Y.
enterocolitica, C.jejuni,
S.typhimurium,M.tuberculosis)
3 Pasteurization Chemical detergent residue 13 = 3 - - - - PRP -Cleaning and
Sanitation program

Physical metal parts/nuts 13 = 3 - - - - PRP -GMP

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/bolts -Preventive
- seals/gaskets 13 = 3 - - - - Maintenance
- silt/soil particles 13 = 3 - - - -
- caked milk 11 = 1 - - - -
- metal filings 11 = 1 - - - -
Biological pathogens 53 = 15 YES YES NO YES CCP CCP PLAN 1
(B.arbotus, E.coli, L.
monocytogenes, Y.
enterocolitica, C.jejuni,
S.typhimurium,M.tuberculosis)
4 Pasteurized Chemical detergent residue 13 = 3 - - - - PRP -Cleaning and
milk storage - lubricants 10.5 = 0.5 - - - - Sanitation program

Physical - gaskets/nuts/oil seal 10.5 = 0.5 - - - - PRP -Preventive

Maintenance
Biological pathogens 51 = 5 YES YES NO NO OPRP OPRP PLAN 4
(B.arbotus, E.coli, L.
monocytogenes, Y.
enterocolitica, C.jejuni,
S.typhimurium,M.tuberculosis)

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FRESH MILK PACKAGING

STEP PROCESS HAZARDS RISK Q1 Q2 Q3 Q4 CLASSIFI CONTROL PLAN

STEP CATION
1 Pumping Chemical detergent residue 13 = 3 - - - - PRP -Cleaning and
pasteurized Sanitation program
milk to
overhead Biological pathogens 51 = 5 YES YES NO NO OPRP OPRP PLAN 5
balance tank (B.arbotus, E.coli, L.
monocytogenes, Y.
enterocolitica, C.jejuni,
S.typhimurium,M.tuberculosis)
Physical metal parts 31 = 3 - - - - PRP -Preventive
- seals/gaskets 13 = 3 - - - - Maintenance
- level sensor 13 = 3 - - - -
probes/wire
2 Pouch Chemical detergent residue 13 = 3 - - - - PRP -Cleaning and
machine Sanitation program
filling tank
Physical level sensor 13 = 3 - - - - PRP -Preventive
probes/wire 13 = 3 - - - - Maintenance
- seals/gaskets
Biological pathogens 51 = 5 YES YES NO NO OPRP OPRP PLAN 6
(B.arbotus, E.coli, L.
monocytogenes, Y.
enterocolitica, C.jejuni,
S.typhimurium,M.tuberculosis)
3 Pouch Chemical detergent residue 13 = 3 - - - - PRP -Cleaning and
forming and Sanitation program
filling
Biological pathogens 53 = 15 YES YES NO NO OPRP OPRP PLAN 7
(B.arbotus, E.coli, L.
monocytogenes, Y.

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enterocolitica, C.jejuni,
S.typhimurium,M.tuberculosis)
Physical metal parts 11 = 1 - - - - PRP -Preventive
- nuts/bolts 13 = 3 - - - - Maintenance
- Teflon, cell/Johnson 13 = 3 - - - - -GMP
tapes
4 Cold storage Chemical cleaning detergent 13 = 3 - - - - PRP -Cleaning and
- Freon gas 10.5= 0.5 - - - - Sanitation program
(refrigerant)
Physical pests/rodents 31 = 3 - - - - PRP -Cleaning and
droppings Sanitation program

Biological yeast and moulds 51 = 5 YES YES NO NO OPRP OPRP PLAN 8

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YOGHURT PROCESSING

STEP PROCESS HAZARDS RISK Q1 Q2 Q3 Q4 CLASSIFI CONTROL PLAN

STEP CATION
1 Pasteurization Chemical detergent residue 13 = 3 - - - - PRP -Cleaning and
Sanitation program

Physical metal parts/nuts /bolts 13 = 3 - - - - PRP -GMP

- seals/gaskets -Preventive
- silt/soil particles 13 = 3 - - - - Maintenance
- caked milk 13 = 3 - - - -
- metal filings 11 = 1 - - - -
11 = 1 - - - -
Biological pathogens 53 = 15 YES YES NO YES CCP CCP PLAN 1
(B.arbotus, E.coli, L.
monocytogenes, Y. enterocolitica,
C.jejuni, S.typhimurium,
M.tuberculosis)
2 Pre-heating Chemical detergent residue 13 = 3 - - - - PRP -Cleaning and
- antibiotics 53 = 15 YES YES NO NO OPRP Sanitation program
- lubricant/grease 10.5 = 0.5 - - - - PRP -OPRP PLAN 9
-Preventive
Maintenance

Physical cleaning 13 = 3 - - - - PRP -GMP

material/fiber/sieves 13 = 3 - - - - -Preventive
- human/animal hair 13 = 3 - - - - Maintenance
- gasket/seals 13 = 3 - - - -
- dust/soil particles 11 = 1 - - - -
- ghee curd
Biological pathogens 51 = 5 YES YES YES - PRP -Cleaning and
(B.arbotus, E.coli, L. Sanitation program
monocytogenes, Y. enterocolitica, -Preventive
C.jejuni, Maintenance

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S.typhimurium,M.tuberculosis) -GMP
yeast and moulds 51 = 5 YES YES YES - PRP
3 Addition of Chemical detergent residue 13 = 3 - - - - PRP -Cleaning and
ingredients Sanitation program
(Sugar,
stabilizer, Physical metal parts/stones 13 = 3 - - - - PRP -GMP
Skim milk - human/animal hair 13 = 3 - - - -
powder) - insects/flies 11 = 1 - - - -
- stirrer parts 10.5 = 0.5 - - - -
- dust/soil particles 11 = 1 - - - -
- hand gloves/nurse 30.5 = 1.5 - - - -
caps
- sieving 11 = 1 - - - -
cloth/material

Biological pathogens (C. 51 = 5 YES YES YES - PRP -Cleaning and

flaccumfaciens) Sanitation program
yeast and moulds 51 = 5 YES YES YES - PRP -GMP
4 Heat Chemical lubricants 10.5 = 0.5 - - - - PRP -Preventive
treatment Maintenance

Physical -seals/gaskets 13 = 3 - - - - PRP -Preventive

-dirt in steam through leaking 10.5 = 0.5 - - - - Maintenance
jacket

Biological pathogens 51 = 5 YES YES NO YES CCP CCP PLAN 2

(B.arbotus, E.coli, L.
monocytogenes, Y. enterocolitica,
C.jejuni,
S.typhimurium,M.tuberculosis)
yeast and moulds 51 = 5 YES YES NO YES CCP

5 Cooling Chemical lubricants 10.5 = 0.5 - - - - PRP -Preventive

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Maintenance

Physical -seals/gaskets 13 = 3 - - - - PRP -Preventive

- dirt in chilling water through 10.5 = 0.5 - - - - Maintenance
leaking jacket

Biological yeast and moulds 51 = 5 YES YES NO NO OPRP OPRP PLAN 10

6 Inoculation Chemical sanitizer 11 = 1 - - - - PRP -Cleaning and

and agitation - lubricants 10.5 = 0.5 - - - - Sanitation program

Physical sanitizing material 11 = 1 - - - - PRP -GMP

- starter culture packmatt 11 = 1 - - - -
- scissors 11 = 1 - - - -
- seals/gasket 13 = 3 - - - -

Biological pathogens 51 = 5 YES YES NO NO OPRP OPRP PLAN 11

(L.monocytogenes,S.aureus,C.jeju
ni,H.pylori,C.difficile,S.pyogenes,
M.tuberculosis)
yeast and moulds 51 = 5 YES YES NO NO OPRP

7 Agitation and Chemical lubricants 10.5 = 0.5 - - - - PRP -Preventive

cooling Maintenance

Physical -seals/gaskets 13 = 3 - - - - PRP -Preventive

-dirt in chilled water through 10.5 = 0.5 - - - - Maintenance
leaking jacket
- metal parts/bolts/nuts 11 = 1 - - - -

Biological - nil

8 Flavouring Chemical detergent residue 13 = 3 - - - - PRP -Cleaning and

and colouring - sanitizing agent 11 = 1 - - - - Sanitation program
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(Flavour and Physical beakers/bottle corks 11 = 1 - - - - PRP -GMP

- human hairs 13 = 3 - - - -
colour) - - - -
- insects/flies 11 = 1 - - - -
- 10.5 = 0.5 - - - -
- stirrer parts 13 = 3 - - - -
- 30.5 = 1.5 - - - -
31 = 3 - - - -
- dust/soil particles 13 = 3

- hand gloves/nurse
caps
-
- glass fragments
- cleaning
- material/fibers

Biological pathogens 51 = 5 YES YES NO NO OPRP OPRP PLAN 12

(L.monocytogenes,S.aureus,C.jeju
ni,H.pylori,C.difficile,S.pyogenes,
M.tuberculosis)
yeast and moulds 51 = 5 YES YES NO NO OPRP

9 Packaging Chemical detergent residue 13 = 3 - - - - PRP -Cleaning and

- sanitizing agent 11 = 1 - - - - Sanitation program
- lubricants 10.5 = 0.5 -Preventive
Maintenance

Physical gasket/seals 13 = 3 - - - - PRP -GMP

- human hair 13 = 3 - - - - -Preventive

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- insects/flies 11 = 1 - - - - Maintenance
- dust/soil particles 13 = 3 - - - -
- hand gloves/nurse 31 = 3 - - - -
caps 13 = 3 - - - -
- metal parts/bolts

Biological pathogens 51 = 5 YES YES NO NO OPRP OPRP PLAN 13

(L.monocytogenes,S.aureus,C.jeju
ni,H.pylori,C.difficile,S.pyogenes,
M.tuberculosis)
yeast and moulds 51 = 5 YES YES NO NO OPRP

10 Cold storage Chemical cleaning detergent 13 = 3 - - - - PRP -Cleaning and

- Freon gas (refrigerant) 10.5 = 0.5 - - - - Sanitation program
-Preventive
Maintenance

Physical pests/rodents droppings 31 = 3 - - - - PRP -Cleaning and

Sanitation program

Biological yeast and moulds 51 = 5 YES YES NO NO OPRP OPRP PLAN 14

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LALA PROCESSING

STEP PROCESS HAZARDS RISK Q1 Q2 Q3 Q4 CLASSIFI CONTROL PLAN

STEP CATION
1 Pasteurization Chemical detergent residue 13 = 3 - - - - PRP -Cleaning and
Sanitation program

Physical metal parts/nuts /bolts 13 = 3 - - - - PRP -GMP

- seals/gaskets -Preventive
- silt/soil particles 13 = 3 - - - - Maintenance
- caked milk 13 = 3 - - - -
- metal filings 11 = 1 - - - -
11 = 1 - - - -
Biological pathogens (B.arbotus, 53 = 15 YES YES NO YES CCP CCP PLAN 1
E.coli, L. monocytogenes, Y.
enterocolitica, C.jejuni,
S.typhimurium,M.tuberculosis)
2 Holding Chemical detergent residue 13 = 3 - - - - PRP -Cleaning and
Sanitation program

Physical gasket/seals 13 = 3 - - - - PRP -Preventive

Maintenance

Biological pathogens (B.arbotus, 51 = 5 YES YES NO NO OPRP OPRP PLAN 15

E.coli, L. monocytogenes, Y.
enterocolitica, C.jejuni,
S.typhimurium,M.tuberculosis)
3 Regenerative Chemical detergent residue 13 = 3 - - - - PRP -Cleaning and
cooling Sanitation program

Physical gasket/seals 13 = 3 - - - - PRP -Preventive

Maintenance

Biological pathogens (B.arbotus, 51 = 5 YES YES NO NO OPRP OPRP PLAN 16

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E.coli, L. monocytogenes, Y.
enterocolitica, C.jejuni,
S.typhimurium,M.tuberculosis)
4 Inoculation/ Chemical sanitizer 11 = 1 - - - - PRP -Cleaning and
agitation - lubricants 10.5 = 0.5 - - - - Sanitation program
- Preventive
Maintenance

Physical sanitizing material 11 = 1 - - - - PRP -GMP

- starter culture packmatt 11 = 1 - - - - - Preventive
- scissors 11 = 1 - - - - Maintenance
- seals/gasket 13 = 3 - - - -

Biological pathogens 51 = 5 YES YES NO NO OPRP OPRP PLAN 17

(L.monocytogenes,S.aureus,C.jejun
i,H.pylori,C.difficile,S.pyogenes,M.
tuberculosis)
yeast and moulds 51 = 5 YES YES NO NO OPRP

5 Agitation/ Chemical lubricants 10.5 = 0.5 - - - - PRP - Preventive

cooling Maintenance

Physical gasket/seals 13 = 3 - - - - PRP - Preventive

- metal parts/bolts/nuts 11 = 1 - - - - Maintenance

Biological - Nil
6 Packaging Chemical detergent residue 13 = 3 - - - - PRP - Cleaning and
- sanitizing agent 11 = 1 - - - - Sanitation program
- lubricants 10.5 = 0.5 - - - - - Preventive
Maintenance

Physical gasket/seals 13 = 3 - - - - PRP -GMP

- human hair 13 = 3 - - - -
- insects/flies 11 = 1 - - - -
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- dust/soil particles 13 = 3 - - - -
- hand gloves/nurse 31 = 3 - - - -
caps 13 = 3 - - - -
- metal parts/bolts
Biological pathogens 51 = 5 YES YES NO NO OPRP OPRP PLAN 18
(L.monocytogenes,S.aureus,C.jejun
i,H.pylori,C.difficile,S.pyogenes,M.
tuberculosis)
yeast and moulds 51 = 5 YES YES NO NO OPRP

7 Cold storage Chemical cleaning detergent 13 = 3 - - - - PRP - Cleaning and

- Freon gas (refrigerant) 10.5 = 0.5 - - - - Sanitation program
- Preventive
Maintenance

Physical pests/rodents droppings 31 = 3 - - - - PRP -GMP

- insects/flies 11 = 1 - - - -

Biological yeast and moulds 51 = 5 YES YES NO NO OPRP OPRP PLAN 19

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 GITHUNGURI DAIRY FARMERS CO-OPERATIVE SOCIETY LTD MILK PLANT
BUTTER PROCESSING

STEP PROCESS HAZARDS RISK Q1 Q2 Q3 Q4 CLASSIFI CONTROL PLAN

STEP CATION
1 Cream Chemical detergent residue 13 = 3 - - - - PRP - Cleaning and
harvesting -obnoxious smell/sep. shoes 11 = 1 - - - - Sanitation program
- Preventive
Maintenance
Physical gasket/seals 13 = 3 - - - - PRP -GMP
- human hair 13 = 3 - - - - - Preventive
- insects/flies 11 = 1 - - - - Maintenance
- dust/soil particles 13 = 3 - - - -
- hand gloves/nurse caps 31 = 3 - - - -
- metal parts/bolts/nuts 13 = 3 - - - -
- cleaning material 13 = 3 - - - -

Biological pathogens 53 = 15 YES YES NO NO OPRP OPRP PLAN 20

(B.arbotus,E.faecium,E. faecalis)
2 Raw cream Chemical detergent residue 13 = 3 - - - - PRP - Cleaning and
standardiza Sanitation program
tion Physical cleaning material/fibers 13 = 3 - - - - PRP -GMP
- human hair 13 = 3 - - - -
- stirrer parts 10.5 = 0.5 - - - -
- dust/soil particles 13 = 3 - - - -
- hand gloves/nurse caps 30.5 = 1.5 - - - -

Biological pathogens 53 = 15 YES YES NO NO OPRP OPRP PLAN 21

(B.arbotus,E.faecium,E. faecalis)
3 Cream Chemical detergent residue 13 = 3 - - - - PRP - Cleaning and
pasteurizati - lubricants 10.5 = 0.5 - - - - Sanitation program
on - Preventive
Maintenance

Physical -seals/gaskets 13 = 3 - - - - PRP - Preventive

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-dirt in steam through leaking 10.5 = 0.5 - - - - Maintenance
jacket

Biological pathogens 51 = 5 YES YES NO YES CCP CCP PLAN 4

(B.arbotus,E.faecium,E. faecalis)
yeast and moulds 51 = 5 YES YES NO YES CCP

4 Cooling Chemical - lubricants 10.5 = 0.5 - - - - PRP - Cleaning and

Sanitation program

Physical -seals/gaskets 13 = 3 - - - - PRP - Preventive

- dirt in chilling water through 10.5 = 0.5 - - - - Maintenance
leaking jacket

Biological yeast and moulds 51 = 5 YES YES NO NO OPRP OPRP PLAN 22

5 Aging Chemical detergent residue 13 = 3 - - - - PRP - Cleaning and

Sanitation program

Physical cleaning material/fibers 13 = 3 - - - - PRP -GMP

- human hair 13 = 3 - - - -
- insects/pests 11 = 1 - - - -
- dust/soil particles 13 = 3 - - - -
- hand gloves/nurse caps 30.5 = 1.5 - - - -

Biological yeast and moulds 51 = 5 YES YES NO NO OPRP OPRP PLAN 23

6 Churning Chemical detergent residue 13 = 3 - - - - PRP - Cleaning and

and salting - sanitizing residue 13 = 3 - - - - Sanitation program

Physical cleaning material/fibers 13 = 3 - - - - PRP -GMP

- human hair/nails 13 = 3 - - - -
- impurities in salt 11 = 1 - - - -
- dust/soil particles 13 = 3 - - - -

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- hand gloves/nurse caps 30.5 = 1.5 - - - -

Biological pathogens 51 = 5 YES YES NO NO OPRP OPRP PLAN 24

(L.monocytogenes,S.aureus,C.jejuni,
H.pylori,C.difficile,S.pyogenes,M.tu
berculosis)
yeast and moulds 51 = 5 YES YES NO NO OPRP

7 Working Chemical detergent residue 13 = 3 - - - - PRP - Cleaning and

and - sanitizer residue 13 = 3 - - - - Sanitation program
molding
Physical nuts/bolts 13 = 3 - - - - PRP -GMP
- human hair/nails 13 = 3 - - - - - Preventive
- pieces of cutting wire 11 = 1 - - - - Maintenance
- dust/soil particles 13 = 3 - - - -

Biological pathogens 51 = 5 YES YES NO NO OPRP OPRP PLAN 25

(L.monocytogenes,S.aureus,C.jejuni,
H.pylori,C.difficile,S.pyogenes,M.tu
berculosis)
yeast and moulds 51 = 5 YES YES NO NO OPRP

8 Packaging Chemical detergent residue 13 = 3 - - - - PRP - Cleaning and

- sanitizer residue 13 = 3 - - - - Sanitation program

Physical insects/flies 11 = 1 - - - - PRP -GMP

- human hair/nails 13 = 3 - - - -
- hand gloves/head 30.5 = 1.5 - - - -
covers 13 = 3 - - - -
- dust/soil particles 10.5 = 0.5 - - - -
- scooping spoons
Biological pathogens 51 = 5 YES YES NO NO OPRP OPRP PLAN 26
(L.monocytogenes,S.aureus,C.jejuni,
H.pylori,C.difficile,S.pyogenes,M.tu

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 GITHUNGURI DAIRY FARMERS CO-OPERATIVE SOCIETY LTD MILK PLANT
berculosis)
yeast and moulds 51 = 5 YES YES NO NO OPRP

9 Cold Chemical cleaning detergent 13 = 3 - - - - PRP - Cleaning and

storage - Freon gas (refrigerant) 10.5 = 0.5 - - - - Sanitation program
- Preventive
Maintenance

Physical pests/rodents droppings 31 = 3 - - - - PRP - Cleaning and

- insects/flies 11 = 1 - - - - Sanitation program

Biological yeast and moulds 51 = 5 YES YES NO NO OPRP OPRP PLAN 27

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GHEE PROCESSING

STEP PROCESS HAZARDS RISK Q1 Q2 Q3 Q4 CLASSIFI CONTROL PLAN

STEP CATION
1 Raw cream Chemical detergent residue 13 = 3 - - - - PRP - Cleaning and
standardiza Sanitation program
tion
Physical cleaning material/fibers 13 = 3 - - - - PRP -GMP
- human hair 13 = 3 - - - -
- stirrer parts 10.5 = 0.5 - - - -
- dust/soil particles 13 = 3 - - - -
- hand gloves/nurse caps 30.5 = 1.5 - - - -

Biological pathogens 53 = 15 YES YES NO NO OPRP OPRP PLAN 28

(B.arbotus,E.faecium,E. faecalis)
2 Cooling Chemical lubricants 10.5 = 0.5 - - - - PRP - Preventive
Maintenance

Physical -seals/gaskets 13 = 3 - - - - PRP - Preventive

- dirt in chilling water through 10.5 = 0.5 - - - - Maintenance
leaking jacket

Biological yeast and moulds 51 = 5 YES YES NO NO OPRP OPRP PLAN 29

3 Aging Chemical detergent residue 13 = 3 - - - - PRP - Cleaning and

Sanitation program

Physical cleaning material/fibers 13 = 3 - - - - PRP -GMP

- human hair 13 = 3 - - - -
- insects/pests 11 = 1 - - - -
- dust/soil particles 13 = 3 - - - -

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- hand gloves/nurse caps 30.5 = 1.5 - - - -

Biological yeast and moulds 51 = 5 YES YES NO NO OPRP OPRP PLAN 30

4 Churning Chemical detergent residue 13 = 3 - - - - PRP - Cleaning and

and - sanitizer residue 13 = 3 - - - - Sanitation program
washing
Physical cleaning material/fibers 13 = 3 - - - - PRP -PRP
- human hair 13 = 3 - - - -
- dust/soil particles 13 = 3 - - - -
- hand gloves/nurse caps 30.5 = 1.5 - - - -

Biological pathogens 53 = 15 YES YES NO NO OPRP OPRP PLAN 31

(L.monocytogenes,S.aureus,C.jejuni,
H.pylori,C.difficile,S.pyogenes,M.tu
berculosis)
yeast and moulds 51 = 5 YES YES NO NO OPRP

5 Heating Chemical detergent residue 13 = 3 - - - - PRP - Cleaning and

- lubricants 10.5 = 0.5 - - - - Sanitation program
- Preventive
Maintenance

Physical -seals/gaskets 13 = 3 - - - - PRP - Preventive

-dirt in steam through leaking 10.5 = 0.5 - - - - Maintenance
jacket 11 = 1 -GMP
- human hair/nails

Biological pathogens 53 = 15 YES YES NO YES CCP CCP PLAN 5

(B.arbotus,E.faecium,E. faecalis) 51 = 5 YES YES NO YES CCP
yeast and moulds
6 Cooling Chemical lubricants 10.5 = 0.5 - - - - PRP - Preventive
Maintenance

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 GITHUNGURI DAIRY FARMERS CO-OPERATIVE SOCIETY LTD MILK PLANT

Physical -seals/gaskets 13 = 3 - - - - PRP - Preventive

- dirt in chilling water through 10.5 = 0.5 - - - - Maintenance
leaking jacket

Biological yeast and moulds 53 = 15 YES YES NO NO OPRP OPRP PLAN 32

7 Packing Chemical Nil

Physical human hair 11 = 1 - - - - PRP -GMP

- insects/flies 13 = 3 - - - -
- dust/soil particles 13 = 3 - - - -
- hand gloves/nurse caps 30.5 = 1.5 - - - -

Biological pathogens 51 = 5 YES YES NO NO OPRP OPRP PLAN 33

(L.monocytogenes,S.aureus,C.jejuni,
H.pylori,C.difficile,S.pyogenes,M.tu
berculosis)
yeast and moulds 51 = 5 YES YES NO NO OPRP

8 Storage Chemical cleaning detergent 13 = 3 - - - - PRP - Cleaning and

Sanitation program

Physical dust/soil particles 13 = 3 - - - - PRP -GMP

- insects/flies 11 = 1 - - - -

Biological yeast and moulds 51 = 5 YES YES NO NO OPRP OPRP PLAN 34

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 GITHUNGURI DAIRY FARMERS CO-OPERATIVE SOCIETY LTD MILK PLANT

OPRP PLAN

PROCESS HAZARD LIMIT CONTROL MONITORI CORRECTI CORRECTIVE RESPONSI VERIFICA RECORD
MEASURE NG ON ACTION BILITY TION
1 Grading Antibiotic Nil Training of Antibiotic Isolate/evaluat -Communicate Lab QAS RM QC 1
s milk Test per batch e/reject & retrain Assistant
suppliers. /Test per can
2 Preservati <2 ppm Training of H202 Test per Isolate/evaluat -Communicate Lab QAS -RM QC 1
ve (H202) milk sampling plan e/reject & retrain Assistant -H202
suppliers sampling
plan
3 Filtrations Pathogens <1000 - Cleaning Start of every Reclean/evalu -Communicate Operator Production -Inline
(B.arbotus CFU and milk ate & Training Supervisor filters
, E.coli, L. Sanitation in reception(2 -Adhere to records
monocyto line filters hrs stoppage) Cleaning and (OPRP-
genes, Y. Sanitation FORM-
enterocolit program 01)
ica,
C.jejuni,
S.typhimu
rium,M.tu
berculosis
)
4 Past milk Pathogens <10 - Cleaning -Adhere to Isolate/evaluat -Communicate Operator Production PM QC 2.
storage (B.arbotus CFU and Cleaning and e/reject/Repro & Training Supervisor -Tank
, E.coli, L. Sanitation Sanitation cess -Adhere to Seals
monocyto program schedule Cleaning and record
genes, Y. -Securing -Check seals Sanitation (OPRP-
enterocolit tanks program FORM-
ica, 02)
C.jejuni,
S.typhimu -C.I.P
rium,M.tu records

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 GITHUNGURI DAIRY FARMERS CO-OPERATIVE SOCIETY LTD MILK PLANT
berculosis (OPRP-
) FORM-
03)
5 Pumping Pathogens <10 - Cleaning -Adhere to Reprocess -Communicate Operator Production -C.I.P
pasteurized (B.arbotus CFU and Cleaning and & Training Supervisor records
milk to , E.coli, L. Sanitation Sanitation -Adhere to (OPRP-
overhead monocyto program schedule Cleaning and FORM-
balance tank genes, Y. Sanitation 03)
enterocolit program
ica,
C.jejuni,
S.typhimu
rium,M.tu
berculosis
)
6 Pouch Pathogens <10 - Cleaning -Adhere to Reprocess -Communicate Operator Production -C.I.P
machine (B.arbotus CFU and Cleaning and & Training Supervisor records
filling tank , E.coli, L. Sanitation Sanitation -Adhere to (OPRP-
monocyto program schedule Cleaning and FORM-
genes, Y. Sanitation 03)
enterocolit program
ica,
C.jejuni,
S.typhimu
rium,M.tu
berculosis
)
7 Pouch Pathogens <10 - Cleaning -Adhere to Isolate/evaluat -Communicate -Operator -Production -C.I.P
forming and (B.arbotus CFU and Cleaning and e/reject & Training - Supervisor records
filling , E.coli, L. Sanitation Sanitation -Adhere to Engineering - (OPRP-
monocyto program schedule Cleaning and technician Engineering FORM-
genes, Y. -Functional -Daily Sanitation Supervisor 03)
enterocolit U.V light Preventive program
ica, present Maintenance - Adhere to Daily -

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 GITHUNGURI DAIRY FARMERS CO-OPERATIVE SOCIETY LTD MILK PLANT
C.jejuni, programme Preventive Preventive
S.typhimu Maintenance Maintenan
rium,M.tu programme ce Record
berculosis
)
8 Fresh milk Yeast and Nil - Cleaning -Adhere to Isolate/evaluat -Communicate Cold store -Production -
Cold storage moulds and Cleaning and e/reject & Training attendant Supervisor Processing
Sanitation Sanitation/fu -Adhere to hall/cold
program migation Cleaning and stores/free
-Fumigation schedule Sanitation/fumiga zer room
program tion program cleaning
record
(OPRP-
FORM-
04)
-
Fumigatio
n records
(OPRP-
FORM-
05)
9 Yoghurt Antibiotic Nil Antibiotic Test result per Isolate/evaluat -Communicate Lab QAS RM QC 1
milk Pre- s test batch e/reject & Training Assistant
heating
10 Yoghurt yeast and Nil - Cleaning -Adhere to Isolate/evaluat -Communicate Production -Production Processing
milk moulds and Cleaning and e/reject & Training Assistant Supervisor hall/cold
Cooling Sanitation Sanitation/fu -Adhere to high value stores/free
program migation Cleaning and zer room
-Fumigation schedule Sanitation/fumiga cleaning
program tion program record
(OPRP-
FORM-
04)
-

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 GITHUNGURI DAIRY FARMERS CO-OPERATIVE SOCIETY LTD MILK PLANT
Fumigatio
n records
(OPRP-
FORM-
05)
11 Yoghurt Pathogens <10 -Aseptic - Adhere to Isolate/evaluat -Communicate Production -Production -
starter (L.monoc CFU inoculation aseptic e/reject & Training Assistant Supervisor Fumigatio
culture ytogenes, - Cleaning inoculation -Adhere to high value n records
Inoculation S.aureus,C and procedure Cleaning and (OPRP-
and .jejuni,H.p Sanitation/ -Adhere to Sanitation/fumiga FORM-
agitation ylori,C.dif Fumigation Cleaning and tion program 05)
ficile,S.py program Sanitation/fu
ogenes,M. migation
tuberculos schedule
is)
<10
-Yeast and CFU
moulds
12 Flavouring Pathogens <10 -Aseptic - Adhere to Isolate/evaluat -Communicate Production -Production -
and (L.monoc CFU flavouring aseptic e/reject & Training Assistant Supervisor Fumigatio
colouring ytogenes, and flavouring -Adhere to high value n records
S.aureus,C colouring and colouring Cleaning and (OPRP-
.jejuni,H.p - Cleaning procedure Sanitation/fumiga FORM-
ylori,C.dif and -Adhere to tion program 05)
ficile,S.py Sanitation/ Cleaning and
ogenes,M. Fumigation Sanitation/fu
tuberculos program migation
is) <10 schedule
-Yeast and CFU
moulds
13 Yoghurt Pathogens <10 -Aseptic - Adhere to Isolate/evaluat -Communicate Production -Production -Yoghurt
packing (L.monoc CFU packaging aseptic e/reject & Training Assistant Supervisor cup/bottle
ytogenes, - Cleaning packaging -Adhere to high value filler
S.aureus,C and procedure Cleaning and cleaning

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 GITHUNGURI DAIRY FARMERS CO-OPERATIVE SOCIETY LTD MILK PLANT
.jejuni,H.p Sanitation/ -Adhere to Sanitation/fumiga records
ylori,C.dif Fumigation Cleaning and tion program (OPRP-
ficile,S.py program Sanitation/fu FORM-
ogenes,M. migation 06)
tuberculos schedule -
is) Fumigatio
-Yeast and <10 n records
moulds CFU (OPRP-
FORM-
05)
14 Yoghurt Yeast and <10 - Cleaning -Adhere to Isolate/evaluat -Communicate Cold store -Production Processing
Cold storage moulds CFU and Cleaning and e/reject & Training attendant Supervisor hall/cold
Sanitation Sanitation/fu -Adhere to stores/free
program migation Cleaning and zer room
-Fumigation schedule Sanitation/fumiga cleaning
program tion program record
(OPRP-
FORM-
04)
-
Fumigatio
n records
(OPRP-
FORM-
05)
15 Lala milk Pathogens <10 - Cleaning Start of every Isolate/evaluat -Communicate Operator Production -C.I.P
Holding (B.arbotus CFU and milk e/reject & Training Supervisor records
, E.coli, L. Sanitation projection for -Adhere to (OPRP-
monocyto program lala (2 hrs Cleaning and FORM-
genes, Y. stoppage) Sanitation 03)
enterocolit program
ica,
C.jejuni,
S.typhimu

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 GITHUNGURI DAIRY FARMERS CO-OPERATIVE SOCIETY LTD MILK PLANT
rium,M.tu
berculosis
)
16 Regenerativ Pathogens <10 - Cleaning -Adhere to Reprocess -Communicate Operator Production -C.I.P
e cooling (B.arbotus CFU and Cleaning and & Training Engineering Supervisor record
, E.coli, L. Sanitation Sanitation -Adhere to technician - (OPRP-
monocyto program schedule Cleaning and Engineering FORM-
genes, Y. -Preventive -Daily Sanitation Supervisor 03)
enterocolit maintenance Preventive program
ica, programme Maintenance -Adhere to Daily -
C.jejuni, programme Preventive Preventive
S.typhimu Maintenance Maintenan
rium,M.tu programme ce Record
berculosis
)
17 Lala starter Pathogens <10 -Aseptic - Adhere to Isolate/evaluat -Communicate Production -Production Processing
culture (L.monoc CFU inoculation aseptic e/reject & Training Assistant Supervisor hall/cold
Inoculation ytogenes, - Cleaning inoculation -Adhere to high value stores/free
and S.aureus,C and procedure Cleaning and zer room
agitation .jejuni,H.p Sanitation/ -Adhere to Sanitation/fumiga cleaning
ylori,C.dif Fumigation Cleaning and tion program record
ficile,S.py program Sanitation/fu (OPRP-
ogenes,M. migation FORM-
tuberculos schedule 04)
is) -
Fumigatio
-Yeast and <10 n records
moulds CFU (OPRP-
FORM-
05)
18 Lala Pathogens <10 -Aseptic - Adhere to Isolate/evaluat -Communicate Production -Production -C.I.P
packing (L.monoc CFU packaging aseptic e/reject & Training Assistant Supervisor record
ytogenes, - Cleaning packaging -Adhere to high value (OPRP-
S.aureus,C and procedure Cleaning and FORM-

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 GITHUNGURI DAIRY FARMERS CO-OPERATIVE SOCIETY LTD MILK PLANT
.jejuni,H.p Sanitation/ -Adhere to Sanitation/fumiga 03)
ylori,C.dif Fumigation Cleaning and tion program
ficile,S.py program Sanitation/fu -
ogenes,M. migation Fumigatio
tuberculos schedule n records
is)

-Yeast and <10

moulds CFU
19 Lala Cold Yeast and <10 - Cleaning -Adhere to Isolate/evaluat -Communicate Cold store -Production Processing
storage moulds CFU and Cleaning and e/reject & Training attendant Supervisor hall/cold
Sanitation Sanitation/fu -Adhere to stores/free
program migation Cleaning and zer room
-Fumigation schedule Sanitation/fumiga cleaning
program tion program record
(OPRP-
FORM-
04)
-
Fumigatio
n records
(OPRP-
FORM-
05)
20 Cream Pathogens <10 - Cans -Adhere to Isolate/evaluat -Communicate Operator Production - Cans
harvesting (B.arbotus CFU Cleaning cans Cleaning e/reject & Training Supervisor Cleaning
,E.faecium and and Sanitation -Adhere to and
,E. Sanitation procedure Cleaning and sanitation
faecalis) procedure Sanitation record
program (OPRP-
FORM-
07)

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 GITHUNGURI DAIRY FARMERS CO-OPERATIVE SOCIETY LTD MILK PLANT
21 Raw cream Pathogens <10 - Cans -Adhere to Isolate/evaluat -Communicate Operator Production - Cans
standardizat (B.arbotus CFU Cleaning cans Cleaning e/reject & Training Supervisor Cleaning
ion ,E.faecium and and Sanitation -Adhere to and
,E. Sanitation procedure Cleaning and sanitation
faecalis) procedure Sanitation record
program (OPRP-
FORM-
07)
22 Cream yeast and <10 - Cleaning -Adhere to Isolate/evaluat -Communicate Production -Production Processing
cooling for moulds CFU and Cleaning and e/reject & Training Assistant Supervisor hall/cold
butter Sanitation Sanitation/fu -Adhere to high value stores/free
program migation Cleaning and zer room
-Fumigation schedule Sanitation/fumiga cleaning
program tion program record
(OPRP-
FORM-
04)
-
Fumigatio
n records
(OPRP-
FORM-
05)
23 Cream yeast and <10 - Cleaning -Adhere to Isolate/evaluat -Communicate Production -Production Processing
aging for moulds CFU and Cleaning and e/reject & Training Assistant Supervisor hall/cold
butter Sanitation Sanitation/fu -Adhere to high value stores/free
program migation Cleaning and zer room
-Fumigation schedule Sanitation/fumiga cleaning
program tion program record
(OPRP-
FORM-
04)
-
Fumigatio

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 GITHUNGURI DAIRY FARMERS CO-OPERATIVE SOCIETY LTD MILK PLANT
n records
(OPRP-
FORM-
05)
24 Butter Pathogens <10 -Aseptic - Adhere to Isolate/evaluat -Communicate Production -Production - Butter
Churning (L.monoc CFU handling aseptic e/reject & Training Assistant Supervisor churn and
and salting ytogenes, - Cleaning handling -Adhere to high value molder
S.aureus,C and procedure Cleaning and cleaning
.jejuni,H.p Sanitation/ -Adhere to Sanitation/fumiga record
ylori,C.dif Fumigation Cleaning and tion program (OPRP-
ficile,S.py program Sanitation/fu FORM-
ogenes,M. migation 08)
tuberculos <10 schedule -
is) CFU Fumigatio
-Yeast n records
and (OPRP-
moulds FORM-
05)
25 Butter Pathogens <10 -Aseptic - Adhere to Isolate/evaluat -Communicate Production -Production - Butter
Working (L.monoc CFU handling aseptic e/reject & Training Assistant Supervisor churn and
and molding ytogenes, - Cleaning handling -Adhere to high value molder
S.aureus,C and procedure Cleaning and cleaning
.jejuni,H.p Sanitation/ -Adhere to Sanitation/fumiga records
ylori,C.dif Fumigation Cleaning and tion program (OPRP-
ficile,S.py program Sanitation/fu FORM-
ogenes,M. migation 08)
tuberculos <10 schedule -
is) CFU Fumigatio
-Yeast and n records
moulds (OPRP-
FORM-
05)

26 Butter Pathogens <10 -Aseptic - Adhere to Isolate/evaluat -Communicate Production -Production Processing

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 GITHUNGURI DAIRY FARMERS CO-OPERATIVE SOCIETY LTD MILK PLANT
Packaging (L.monoc CFU handling aseptic e/reject & Training Assistant Supervisor hall/cold
ytogenes, - Cleaning handling -Adhere to high value stores/free
S.aureus,C and procedure Cleaning and zer room
.jejuni,H.p Sanitation/ -Adhere to Sanitation/fumiga cleaning
ylori,C.dif Fumigation Cleaning and tion program record
ficile,S.py program Sanitation/fu (OPRP-
ogenes,M. migation FORM-
tuberculos <10 schedule 04)
is) CFU -
-Yeast and Fumigatio
moulds n records
(OPRP-
FORM-
05)
27 Butter Cold Yeast and <10 - Cleaning -Adhere to Isolate/evaluat -Communicate Cold store -Production Processing
storage moulds CFU and Cleaning and e/reject & Training attendant Supervisor hall/cold
Sanitation Sanitation/fu -Adhere to stores/free
program migation Cleaning and zer room
-Fumigation schedule Sanitation/fumiga cleaning
program tion program record
(OPRP-
FORM-
04)
-
Fumigatio
n records
(OPRP-
FORM-
05)
28 Raw cream Pathogens <10 - Cans -Adhere to Isolate/evaluat -Communicate Operator Production - Cans
standardizat (B.arbotus CFU Cleaning cans Cleaning e/reject & Training Supervisor Cleaning
ion for ghee ,E.faecium and and Sanitation -Adhere to and
,E. Sanitation procedure Cleaning and Sanitation
faecalis) procedure Sanitation Records

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program (OPRP-
FORM-
07)
29 Cream Yeast and <10 - Cleaning -Adhere to Isolate/evaluat -Communicate Production -Production Processing
cooling for moulds CFU and Cleaning and e/reject & Training Assistant Supervisor hall/cold
ghee Sanitation Sanitation/fu -Adhere to high value stores/free
program migation Cleaning and zer room
-Fumigation schedule Sanitation/fumiga cleaning
program tion program record
(OPRP-
FORM-
04)
-
Fumigatio
n records
(OPRP-
FORM-
05)
30 Cream yeast and <10 - Cleaning -Adhere to Isolate/evaluat -Communicate Production -Production Processing
aging for moulds CFU and Cleaning and e/reject & Training Assistant Supervisor hall/cold
ghee Sanitation Sanitation/fu -Adhere to high value stores/free
program migation Cleaning and zer room
-Fumigation schedule Sanitation/fumiga cleaning
program tion program record
(OPRP-
FORM-
04)
-
Fumigatio
n records
(OPRP-
FORM-
05)
31 Butter Pathogens <10 -Aseptic - Adhere to Isolate/evaluat -Communicate Production -Production - Butter

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Churning (L.monoc CFU handling aseptic e/reject & Training Assistant Supervisor churn and
and washing ytogenes, - Cleaning handling -Adhere to high value molder
for ghee S.aureus,C and procedure Cleaning and cleaning
.jejuni,H.p Sanitation/ -Adhere to Sanitation/fumiga record
ylori,C.dif Fumigation Cleaning and tion program (OPRP-
ficile,S.py program Sanitation/fu FORM-
ogenes,M. migation 08)
tuberculos schedule -
is) Fumigatio
-Yeast <10 n records
and CFU (OPRP-
moulds FORM-
05)
32 Ghee yeast and <10 - Cleaning -Adhere to Isolate/evaluat -Communicate Production -Production Processing
Cooling moulds CFU and Cleaning and e/reject & Training Assistant Supervisor hall/cold
Sanitation Sanitation/fu -Adhere to high value stores/free
program migation Cleaning and zer room
-Fumigation schedule Sanitation/fumiga cleaning
program tion program record
(OPRP-
FORM-
04)
-
Fumigatio
n records
(OPRP-
FORM-
05)
33 Ghee Pathogens <10 -Aseptic - Adhere to Isolate/evaluat -Communicate Production -Production Processing
Packaging (L.monoc CFU handling aseptic e/reject & Training Assistant Supervisor hall/cold
ytogenes, - Cleaning handling -Adhere to high value stores/free
S.aureus,C and procedure Cleaning and zer room
.jejuni,H.p Sanitation/ -Adhere to Sanitation/fumiga cleaning
ylori,C.dif Fumigation Cleaning and tion program record

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 GITHUNGURI DAIRY FARMERS CO-OPERATIVE SOCIETY LTD MILK PLANT
ficile,S.py program Sanitation/fu (OPRP-
ogenes,M. migation FORM-
tuberculos schedule 04)
is) <10 -
-Yeast and CFU Fumigatio
moulds n records
(OPRP-
FORM-
05)
34 Ghee Yeast and <10 - Cleaning -Adhere to Isolate/evaluat -Communicate Cold store -Production Processing
storage moulds CFU and Cleaning and e/reject & Training attendant Supervisor hall/cold
Sanitation Sanitation/fu -Adhere to stores/free
program migation Cleaning and zer room
-Fumigation schedule Sanitation/fumiga cleaning
program tion program record
(OPRP-
FORM-
04)
-
Fumigatio
n records
(OPRP-
FORM-
05)

CCP PLAN
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 GITHUNGURI DAIRY FARMERS CO-OPERATIVE SOCIETY LTD MILK PLANT

PROCESS HAZARD CRITICAL CONTROL MONITOR CORRECT CORRECTIVE RESPONSI VERIFICA RECORD
LIMIT MEASURE ING ION ACTION BILITY TION
1 Raw milk Pathogen Temperature Attainment Accurate Isolate and -Proper -Operator -Production -PHE Past
pasteurizati (B.arbotus >720C Time of Past temp Temp reprocess maintenance of Supervisor log sheet
on , E.coli, L. >15 sec and holding readings flow diversion (CCP-
monocyto time every 30 valve. -Plant FORM
genes, Y. min. -Calibration of Maintenanc 01)
enterocolit gauges e Engineer QAM Preventive
ica, Maintenan
C.jejuni, ce record/
S.typhimu Calibratio
rium,M.tu n records
berculosis
)
2 Yoghurt Pathogens Temperature Attainment Accurate Isolate and -Proper -High value -Production -Batch
milk heat (B.arbotus >850C of heating readings reprocess maintenance of Production Supervisor past log
treatment , E.coli, L. Time >30 temperature from temperature Assistant sheet(CCP
monocyto min and holding temperature gauges -FORM
genes, Y. time gauges and -Calibration of -Plant 02)
enterocolit timer every gauges Maintenanc QAM Preventive
ica, 15 min on e Engineer Maintenan
C.jejuni, attaining ce record/
S.typhimu 850C Calibratio
rium,M.tu n records
berculosis
)
3 Cream Pathogens Temperature Attainment Accurate Isolate/eval -Proper -High value -Production -Batch
pasteurizati (B.arbotus >850C Time of Past temp readings uate and maintenance of Production Supervisor past log
on ,E.faecium >30 min and holding from reprocess temperature Assistant sheet(CCP
,E. time temperature gauges -FORM
faecalis) gauges and -Calibration of -Plant 03)
timer every gauges Maintenanc QAM Preventive
15 min on e Engineer Maintenan

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 GITHUNGURI DAIRY FARMERS CO-OPERATIVE SOCIETY LTD MILK PLANT
attaining ce record/
850C Calibratio
n records

4 Ghee butter Pathogens Temperature Attainment Accurate Isolate and -Proper -High value -Production -Ghee pot
heat (L.monoc >1100C of heating hourly reprocess maintenance of Production Supervisor log
treatment ytogenes, temperature readings temperature Assistant sheet(CCP
S.aureus,C from gauges -FORM
.jejuni,H.p temperature -Calibration of -Plant 04)
ylori,C.dif gauges gauges Maintenanc QAM Preventive
ficile,S.py e Engineer Maintenan
ogenes,M. ce record/
tuberculos Calibratio
is) n records

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LIST OF PATHOGENS

Raw milk Human Cream Additives

(Sugar/stabilizer/colour/flavour
fruit pulps)
Brucella arbotus Listeria monocytogenes Brucella arbotus Curtobacterium flaccumfaciens
Salmonella typhimurium Staphylococcus aureus Enterococcus faecium
Campylobacter jejuni Campylobacter jejuni Enterococcus faecalis
Escherichia coli Helicobacter pylori Mycobacterium tuberculosis
Yesinia enterocolitica Clostridium difficile
Listeria monocytogenes Streptococcus pyogenes
Mycobacterium tuberculosis Mycobacterium tuberculosis

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