Pasteurized whole milk

HACCP Case study

List of ingredients and incoming material

Process/ Product name: Pasteurized whole milk
Product category: Ready to drink

Dairy ingredients
Raw milk

Other
ingredients

----

Packaging material
Plastic bottles

Pasteurized milk product description

Common Name:

Pasteurized whole milk.

Preparation instructions:

Direct consume.

Type of package:

Plastic bottles

Shelf life and storage temperature:

3 days at 4-6C

Sale location:

Retail

Labeling instructions:

keep cool, lot

code on production
date.

Date:

Approved by:

Process Flow Diagram

Product name: pasteurized
whole milk

Raw milk

Packaging material

Receiving

Receiving

Refrigerated
storage
At 6C

Clarification
Standardization

Homogenization
Pasteurization
72.6C/15s. and
Cooling < 6C

Filling
Storage < 6C

Distribution
< 6C

Storage at ambient
temperature &dry

Hazard Analysis
PASTEURIZED WHOLE MILK
Process Step
Receiving
Raw milk

HAZARDS

(B)Salmonella
Mycobact. bovis
L. monocytogenes
E. coli O157:H7
S. aureus

PREVENTATIVE MEASURES
Approved suppliers
audit
specifications
Refrigeration since milking

(C) Residues of
antibiotics
(P) None

Approved suppliers
Control at farm level

Hazard Analysis

PASTEURIZED WHOLE MILK

Process Step

HAZARDS

Cooling

(B) Environmental

Homogenization

contamination
( C) Cleaning
residues
(B) Crossed
contamination
with equipment
(C) Residues of
equipments
sanitization
agents

PREVENTATIVE MEASURES
GMP

SSOPs

Hazard Analysis
PASTEURIZED WHOLE MILK
Process Step

Pasteurization

Cooling
Filling &Packing

Distribution

HAZARDS

(B) Survival of
pathogens due
to inefficient
time/
temperature.
(B) Environmental
contamination
(B)
Recontamination
with pathogens

PREVENTATIVE MEASURES

proper time and temperature

(
C/ s.)

GMP
GMP

(B) Growth of
Control of time and temperature, less than
microorganisms
6 C
due to abuse

Determination of Critical Control Points (CCP)

PASTEURIZED WHOLE MILK PROCESS
Process Step

HAZARDS

PREVENTATIVE
MEASURES

ANSWERS TO THE
DECISION TREE

CCPs
?

Q1
Q1 Q2 Q3 Q4
Reception of raw
milk

Salmonella
Mycobact. bovis
L. monocytogenes
E. coli O157:H7
S. aureus

Residues of
antibiotics
Cooling

Environmental
contaminants

SQA

Audit. specifications
Cooling since
milking
Control at farm level.

GMP

Determination of Critical Control Points (CCP)

PASTEURIZED WHOLE MILK PROCESS

Process Step

Homogenization

HAZARDS

PREVENTATIVE
MEASURES

(B) Cross
contamination
by equipment

SSOPs

( C) Residue of
cleaning&
sanitizing
agents

SSOPs

(P) None

ANSWERS TO THE
DECISION TREE
Q1 Q2 Q3 Q4
Y

CCPs?

No

Determination of Critical Control Points (CCP)

PASTEURIZED WHOLE MILK PROCESS
Process Step
Pasteurization

Cooling
Filling & Packing

Distribution

HAZARDS
Survival of
pathogens
(insufficient
time/temp.)
Environmental
contaminants
Recontamination
with
pathogens
Contamination
from packing
material
Growth
of
bacteria

PREVENTATIVE
MEASURES
proper time and

ANSWERS TO THE
DECISION TREE
Q1 Q2 Q3 Q4
Y
Y

CCPs?
Y

temperature
GMP

SSOPs

washing of bottles
at 100C
Control of time
and

Critical Limits in the PASTEURIZED WHOLE MILK

process
CCP

Hazards

Preventative
measures

Critical
Limits

CCP1(B)
Pasteurization

Survival of

Correct time

Temp. 72.6 C

pathogens

and
temperature

CCP2(B)
Distribution

Growth of
bacteria

Control of
temperature

Time: 15 sec.
Target value :
73 C - 15 sec.

4 - 6 C

Monitoring of CCPs in the Pasteurized Whole Milk process

CCP

CL

CCP1(B)
Pasteurization

Time, T

CCP2(B)
Distribution

Time, T

Monitoring
Method

Freq.

Response

Thermo-

Continuou
s.

Process

Every 4 h.

Person in
charge

Record
Thermometer

Superviso
r.

Corrective Actions in the Pasteurized Whole Milk Process

C C P

CL

Pasteurization 72.6 C
15 sec.

Deviation
Temperature
between
72.6
73C

Corrective Actions
To prevent deviation
Re-process milk
Record and inform to quality control and
maintenance

Target
Value

Responsible: automatic action, but followed

by production supervisor.

73C /
15sec.

To correct deviation:
Stop the process
Allot milk to another process, or reprocess if feasible.
Adjust process: review thermal record
and return valve; gauge temperature sensor

Corrective Actions in the Pasteurized Whole Milk Process

C C P
Distribution

CL
4 - 8 C
6 C
Target
value

Deviation
Temperature
higher
than 8C

Corrective Actions
To prevent deviation
Revise cold equipment
Gauge thermometer
Record and inform
Responsible: carrier - seller
To correct deviation
Assess product and decide on its
allotment
Review/correct equipment