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 Other ingredients Packaging material

Raw milk

----

Plastic bottles

Approved by:

Date:

Pasteurized milk product description

Common Name: Pasteurized whole milk.

Preparation instructions:
Type of package: Shelf life and storage temperature: Sale location: Labeling instructions:

Direct consume.
Plastic bottles 4 days at 4-6C Wholesale , Retail keep cool, lot code on production date.

Approved by : Date :

Process Flow Diagram Product name: pasteurized whole milk

Raw milk

Packaging material

Receiving
Refrigerated storage At 6C

Receiving Storage at ambient temperature &dry

Clarification
Homogenization

Standardization

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

Filling

Developed by: Approved by: Date:

Storage < 6C

Distribution < 6C

Hazard Analysis
PASTEURIZED WHOLE MILK
Process Step
Receiving Raw milk

HAZARDS

PREVENTATIVE MEASURES
Approved suppliers SQA specifications Refrigeration since milking

(B) Presence 0f Pathogens (Salmonella Mycobact. bovis L. monocytogenes E. coli O157:H7 S. aureus) .

(C) Residues of antibiotics (P) None

Approved suppliers Control at farm level ------------------------

Hazard Analysis

PASTEURIZED WHOLE MILK

Process Step HAZARDS PREVENTATIVE MEASURES

Storage at 6C

(B) Growth or contamination of m.o.

( C) Cleaning residues

GMP

Homogenization

(B) contamination (C) Residues of equipments sanitization agents

SSOPs

Hazard Analysis
PASTEURIZED WHOLE MILK
Process Step HAZARDS PREVENTATIVE MEASURES

Pasteurization & cooling

(B) Survival of pathogens due to inefficient time/ temperature. (B)Post pasteurization contamination

proper time and temperature ( C/ s.)

Filling &Packing

GMP

Distribution

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

Determination of Critical Control Points (CCP) PASTEURIZED WHOLE MILK PROCESS

Process Step HAZARDS PREVENTATIVE MEASURES SQA Audit. specifications Cooling since milking Control at farm level. ANSWERS TO THE DECISION TREE Q1 Q2 Q3 Q4 Y N Y Y CCPs ? N

Reception of raw milk

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

Residues of antibiotics

Cooling

contaminants

GMP

Determination of Critical Control Points (CCP) PASTEURIZED WHOLE MILK PROCESS

Process Step

HAZARDS

PREVENTATIVE MEASURES

ANSWERS TO THE DECISION TREE Q1 Q2 Q3 Q4

Y N Y Y

CCPs?

Homogenization

(B) contamination

GMP

No

( C) Residue of cleaning& sanitizing agents

GMP

(P) None

Determination of Critical Control Points (CCP) PASTEURIZED WHOLE MILK PROCESS

Process Step HAZARDS PREVENTATIVE MEASURES ANSWERS TO THE DECISION TREE Q1 Q2 Q3 Q4 CCPs?

Pasteurization

Survival of pathogens (insufficient time/temp.)

Recontamination with pathogens Contamination from packing material

proper time and

temperature GMP Aseptic Cabinet

Filling & Packing

washing of bottles at 100C Control of time and temperature Y N Y N

Distribution

Growth of bacteria

Critical Limits in the PASTEURIZED WHOLE MILK process

CCP Hazards Preventative measures
Proper time and temperature

Critical Limits
Temp. 72.6 C Time: 15 sec. Target value : 73 C - 15 sec.

CCP1(B) Pasteurization

Survival of pathogens

CCP2(B) Distribution

Growth of bacteria

Control of temperature

4 - 6 C

Monitoring of CCPs in the Pasteurized Whole Milk process

CCP

CL
Method

Monitoring
Freq. Continuou s. Response Process

CCP1(B) Pasteurization

Time, T

Thermo-

Record
CCP2(B) Distribution Time, T Thermometer Every 4 h.

Superviso r.
Person in charge

Corrective Actions in the Pasteurized Whole Milk Process

C C P Pasteurizatio n CL 72.6 C 15 sec. Deviation Temperature between 72.6 73C Corrective Actions To prevent deviation Repasteurization

Record and inform to quality control and maintenance

Responsible: automatic action, but followed by production supervisor.

Target Value

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 Record and inform to quality control.

Corrective Actions in the Pasteurized Whole Milk Process

C C P CL Deviation Corrective Actions

Distribution

4 - 8 C
6 C Target value

Temperature
higher than 8C

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 Record. Responsible: carrier, seller

HACCP Plan CHART

ccp No. Critical limit Montioring procedures
Thermo- Record Continuous. Process Supervisor.

Corrective action
Stop the process Allot milk to another process, or reprocess if feasible. Adjust process: review thermal record and return valve; gauge temperature sensor Record and inform to quality control.

Verification
-Testing

Record keeping Verification records

Monitoring records Thermal chart.

Pasteurization 72.6 C (CCP1)

15 sec. Target Value

records.
-Monitoring

records.
-Testing

73C /15sec.

Product deviation records.

Distribution (CCP2)

4 - 8 C 6 C Target value

Thermo-meter Every 4 h Person in charge

Assess product and decide on its allotment . Review/correc t equipment Record.

-Testing

records. -Monitoring records. -Testing

Verificaion records Monitoring records Product deviation records