39197964 haccp plan dairy plant isa

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INDUSTRIAL PROJECT

THE DESIGN OF A HACCP PLAN FOR THE ISA DAIRY PLANT

DECEMBER 2008

A report work by:

Jenifer Lourdu Edward,

Ravichandran Suresh &

Sunil Pachar

Master 2- Industrial Biotechnology Management

Research Advisors: Celine Casagrande and Cecile Goutte

1

INDUSTRIAL PROJECT

THE DESIGN OF A HACCP PLAN FOR THE ISA DAIRY PLANT

DECEMBER 2008

A report work by:

Jenifer Lourdu Edward,


Sunil Pachar

Master 2- Industrial Biotechnology Management

Research Advisors: Celine Casagrande and Cecile Goutte

2

ABSTRACT

Title: The Design of a HACCP Plan for the ISA Dairy Plant

Writers: Jenifer Lourdu Edward,


Sunil Pachar

Research Advisors: Celine Casagrande,

Cecile Goutte

Date: December 2008

No. Of Pages: 52

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ACKNOWLEDGEMENTS

We sincerely thank Celine Casagrande and Cecile Goutte, our research advisers for their

professional direction and the time they spent with us to complete this study successfully.

In addition we would also like to express our gratitude to Mr. Tanguy Bantas for guiding us the

HACCP procedures.

Finally, we thank ISA for entrusting us with this project and it has been a wonderful experience

working for them.

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TABLE OF CONTENTS

1. INTRODUCTION ...................................................................................................................................... 10

2. PURPOSE OF STUDY ............................................................................................................................... 11

2.1 Statement of the study .................................................................................................................... 11

2.2 Needs for the study .......................................................................................................................... 11

2.3 Objectives......................................................................................................................................... 11

2.4 Problems Encountered .................................................................................................................... 11

3. METHODOLOGY & RESULTS ................................................................................................................... 12

3.1 Principles of HACCP .......................................................................................................................... 12

3.2 Application ....................................................................................................................................... 13

3.2.1 Assemble HACCP team .............................................................................................................. 13

3.2.2 Describe product ....................................................................................................................... 14

3.2.3 Identify intended use ................................................................................................................ 19

3.2.4 Construct flow diagram ............................................................................................................. 19

3.2.5 On-site confirmation of flow diagram....................................................................................... 20

3.2.6 List all potential hazards associated with each step, conduct a hazard analysis, and consider

any measures to control identified hazards ...................................................................................... 20

3.2.7 Determine Critical Control Points ............................................................................................. 23

3.2.8 Establish critical limits for each CCP ......................................................................................... 24

3.2.9 Establish a monitoring system for each CCP ............................................................................. 24

3.2.10 Establish corrective actions .................................................................................................... 25

3.2.11 Establish verification procedures ............................................................................................ 26

3.2.12 Establish Documentation and Record Keeping ....................................................................... 26

4. RECOMMENDATIONS ............................................................................................................................. 26

5. CONCLUSION .......................................................................................................................................... 28

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ANNEX ..................................................................................................................................................... 29

Logic Sequence for Application of HACCP (Diagram 1) ....................................................................... 29

Hazards in Ingredients & Incoming Materials Analysis Chart (Chart 1) .............................................. 30

Hazard Analysis Chart for Cheese Processing (Chart 2) ........................................................................ 32

Risk Assessment for determined hazards (Chart 3) ................................................................................. 38

HACCP Decision tree utilized to determine the critical control points (Diagram 2) ............................. 42

Critical Control Point determination using the decision tree (Chart 4) ................................................. 43

Chart displaying the critical limits for each CCP (Refer Annex, Chart 5) ............................................. 49

6. BIBLIOGRAPHY ....................................................................................................................................... 52

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LIST OF DEFINITIONS

Cleaning - the removal of soil, food residue, dirt, grease or other objectionable matter.

Contaminant - any biological or chemical agent, foreign matter, or other substances not

intentionally added to food which may compromise food safety or suitability.

Contamination - the introduction or occurrence of a contaminant in food or food

environment.

Disinfection - the reduction, by means of chemical agents and/or physical methods, of

the number of micro-organisms in the environment, to a level that does not compromise

food safety or suitability.

Establishment - any building or area in which food is handled and the surroundings

under the control of the same management.

Food hygiene - all conditions and measures necessary to ensure the safety and suitability

of food at all stages of the food chain.

Hazard - a biological, chemical or physical agent in, or condition of, food with the

potential to cause an adverse health effect.

Food handler - any person who directly handles packaged or unpackaged food, food

equipment and utensils, or food contact surfaces and is therefore expected to comply with

food hygiene requirements.

Food safety - assurance that food will not cause harm to the consumer when it is

prepared and/or eaten according to its intended use.

Control: To take all necessary actions to ensure and maintain compliance with criteria

established in the HACCP plan.

Control measure: Any action and activity that can be used to prevent or eliminate a food

safety hazard or reduce it to an acceptable level.

Corrective action: Any action to be taken when the results of monitoring at the CCP

indicate a loss of control.

Critical Control Point (CCP): A step at which control can be applied and is essential to

prevent or eliminate a food safety hazard or reduce it to an acceptable level.

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Critical limit: A criterion which separates acceptability from unacceptability.

Deviation: Failure to meet a critical limit.

Flow diagram: A systematic representation of the sequence of steps or operations used

in the production or manufacture of a particular food item.

HACCP: A system which identifies, evaluates, and controls hazards which are

significant for food safety.

HACCP plan: A document prepared in accordance with the principles of HACCP to

ensure control of hazards which are significant for food safety in the segment of the food

chain under consideration.

Hazard: A biological, chemical or physical agent in, or condition of, food with the

potential to cause an adverse health effect.

Hazard analysis: The process of collecting and evaluating information on hazards and

conditions leading to their presence to decide which are significant for food safety and

therefore should be addressed in the HACCP plan.

Monitor: The act of conducting a planned sequence of observations or measurements of

control parameters to assess whether a CCP is under control.

Step: A point, procedure, operation or stage in the food chain including raw materials,

from primary production to final consumption.

Validation: Obtaining evidence that the elements of the HACCP plan are effective.

Verification: The application of methods, procedures, tests and other evaluations, in

addition to monitoring to determine compliance with the HACCP plan.

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LIST OF TABLES & FIGURES

Table 1: Illustrates the plan of action undertaken to implement the HACCP plan for the

dairy plant. (Page 12)

Table 2: Displays the product characteristics for Tomme cheese and St. Paulin cheese.

(Page 16)

Table 3: Allergen information for Tomme cheese and St.Paulin cheese. (Page 17)

Figure 1: The process flow diagram for both Tomme cheese and St. Paulin is given along

with the CCP’s determined. (Page 18)

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LIST OF ABBREVIATIONS

HACCP: Hazard Analysis Critical Control Point

NASA: National Aeronautics and Space Administration

ISA: Institut Superieur d’Agriculture

CCP: Critical Control Point

CP: Control Points

PRP: Pre Requisite Program

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1. INTRODUCTION

HACCP is an acronym for the Hazard Analysis Critical Control Point. It is a system

that was developed for assuring pathogen-free foods for the space program by the Pillsbury

Company, the U.S. Army, and the National Aeronautics and Space Administration (NASA) in

the 1960s.

The dairy plant at ISA, which produces curd and cheese requires a HACCP plan for its quality

control program and also since it is mandatory in the European Union. The scope of this project

was to establish a HACCP model for the cheese products produced here at this plant. Cheese is a

product that preserves raw milk. Due to the high acidity (low pH value) in the cheese-making

process, the pathogens in the milk are killed. However, in cheese manufacturing, problems

associated with the presence of Listeria monocytogenes, Salmonella enteritidis, Staphylococcus

aureus, Escherichia coli and others have been documented. HACCP was originally developed as

a “zero defects” program and considered to be synonymous with food safety. It is a

straightforward and logical system that uses preventative action to address potential

microbiological, chemical and physical hazards that are identified in the process. HACCP is a

science-based system used to ensure that food safety hazards are controlled to prevent unsafe

food from reaching the consumer.

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2. PURPOSE OF STUDY

2.1 Statement of the study

The purpose of this study is to design a HACCP plan model for a small scale dairy plant at ISA.

This study started on the 15th

of October and finished on the 12th

of December, 08. The study has

been carried out by making observations of the plant environment, and by discussing potential

hazards and other recommendations with the cheese maker and HACCP experts in order to

develop the specific HACCP model.

2.2 Needs for the study

This study is specifically designed for a small-scale cheese plant which has just recently started

functioning and that needs a better quality control system to produce quality, safe cheese.

2.3 Objectives

To set up a specific HACCP plan for this small-scale dairy plant and to document the HACCP

plan in order to demonstrate the effectiveness of its application.

2.4 Problems Encountered

The project spanned for a very limited time and thereby as a result of time constraint a few

experiments could not be carried out (Analysing the chlorine content in water used for cheese

manufacturing). Also the production of cheese did not take place during this period; this resulted

in us having a very limited knowledge about the production method in this plant.

Nevertheless, we committed ourselves in finding the most appropriate HACCP model for this

plant in consultation with our advisers and HACCP experts.

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3. METHODOLOGY & RESULTS

This chapter will discuss the approach we undertook in order to implement the HACCP for the

dairy plant; utilizing the principles and application of HACCP, we have established the HACCP

plan with relevance to cheese making. It will conclude with a report of findings of the

significance of HACCP on cheese processing.

3.1 Principles of HACCP

The HACCP system consists of the following seven principles:

PRINCIPLE 1

Conduct a hazard analysis.

PRINCIPLE 2

Determine the Critical Control Points (CCPs).

PRINCIPLE 3

Establish critical limit(s).

PRINCIPLE 4

Establish a system to monitor control of the CCP.

PRINCIPLE 5

Establish the corrective action to be taken when monitoring indicates that a particular CCP is not

under control.

PRINCIPLE 6

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

PRINCIPLE 7

Establish documentation concerning all procedures and records appropriate to these principles

and their application.

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3.2 Application

The application of HACCP principles consists of the following tasks as identified in the Logic Sequence

for Application of HACCP (See Annex, Diagram 1).

3.2.1 Assemble HACCP team

HACCP Team

a) Jenifer Lourdu Edward

b) Ravichandran Suresh

c) Sunil Pachar

The team also included our research guides namely Celine Casagrande, Cecile

Goutte and also Tanguy Bantas (HACCP expert).

The scope of the study was to implement a HACCP plan for two varieties of cheese produced at

this site namely Tomme Cheese and St. Paulin and to check its efficiency during its next

production. All classes of hazards were put to study during this project (Biological, Chemical

and Physical).

Plan of Action

Action Person in Charge Date

PRP Description Jenifer, Sunil 15th

to 22nd

Oct, 08

Description of Product

Composition Suresh 15/10/08

Physical/Chemical Structure Suresh 15/10/08

Microcidal/Static Temperatures Sunil 15/10/08

Packaging Sunil 15/10/08

Storage Conditions Jenifer 15/10/08

Distribution Methods Jenifer 15/10/08

Intended use of Product Suresh 15/10/08

Construct the flow diagram and describe the

process.

Suresh (Process

Description)

15th

to 22nd

Oct, 08

Design of Building Jenifer 22nd

Oct, 08

On Site Verification

Hazard Analysis

Biological Sunil 15th

Oct to 19th

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Nov, 08

Physical Jenifer 15th

Oct to 19th

Nov, 08

Chemical Suresh 15th

Oct to 19th

Nov, 08

Risk Assessment Jenifer, Sunil, Suresh 19/11/08

Determining CCP’s Jenifer, Sunil, Suresh Nov 19th

to 26th

Establishing Critical Limits Jenifer, Sunil, Suresh Nov 19th

to 26th

Monitoring System for CCP’s Jenifer, Sunil, Suresh Nov 19th

to 26th

Corrective Actions

Verification Procedures N/A

Documentation N/A

Time for report completion Jenifer, Sunil, Suresh Dec 1st to 9

th

Report Submission December 12th

Table 1: Illustrates the plan of action undertaken to implement the HACCP plan for the

dairy plant.

3.2.2 Describe product

Tomme Cheese: Process Description

Cheese making is the process of removing water, lactose and some minerals from milk to

produce a concentrate of milk fat and protein. The essential ingredients for cheese are milk,

rennet, starter cultures and salt. The semi-form gel is formed by adding rennet that causes the

milk protein to aggregate at a certain pH; then it is cut into small curds. Then the whey (mostly

water and lactose) begins to separate from the curds. Acid production from bacterial cultures is

essential to aid in the expulsion of whey from the curd and largely determines the final cheese

moisture, flavour and texture.

The production of Tomme Cheese (a half-pressed and uncooked cheese made with pasteurized

cow’s milk) involves:

The milk is kept chilled (< 4⁰C) in storage tanks prior to production. Before pasteurization, the

milk is passed through heat exchangers (~ 35⁰ to 40⁰ C) and then moved into the pasteurization

tank.

1. Pasteurization

Pasteurization is one of the most important critical control points in the cheese making

process. It helps to increase the shelf life of the product by destroying vegetative

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pathogens in milk. The milk is pasteurized at 72⁰C for a minute. The pasteurized milk is

then cooled down to 30⁰C in the pasteurization tank.

2. Stirring

Two pitchers of 1 l each are taken and into each the starter cultures (Sigma 41 and

Omega) is diluted (1 tube) with the pasteurized milk taken from the tank. The use of

cultures in cheese making is to develop acidity and to promote ripening. It is then poured

into the tank along with Calcium Chloride solution (32 mL) and stirred for 2 minutes at

high speed in the tank.

3. Ripening

Ripening refers to the practice of giving the culture time to begin acid production before

the rennet is added. Ripening is done to ensure the culture is active before the milk is

renneted and development of acidity aids the coagulation process.

The stirred milk is left for ripening in the pasteurization tank for 2 hours at 30⁰C.

4. Addition of Rennet

Casein is the major protein in milk. During cheese production, rennet (25 mL /100 L of

milk), a coagulating enzyme, is stirred into the milk at 30⁰C for 50 minutes. Under

certain acid condition, rennet then separates the casein from the whey and causes the

individual cells of the casein to clump together to form the gel network.

5. Cutting the curded milk

At the beginning, cut to obtain cheese grain as big as corn grain. Wait a few minutes until

the whey rises to the surface. Blend with the cutting equipment for 30 minutes. Wait for a

few minutes and then remove 15 L of whey after which 15 L of water is added. It is then

blended for 10 to 20 minutes. 45 L of whey is then removed for the curd to remain.

6. Moulding

The curd is placed in the moulds. The moulds are placed on a tray under the exit valve of

the pasteurization tank. The valve is opened for the curd to drain into the moulds through

the shovel.

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7. Pressing

Pressing the mass helps to form loose curd particles into a compact mass and expel whey.

Pressing is performed by placing the lids (flat upside down) on top of the wrapped curds.

A stainless plate is used to segregate each layer of curd (Each layer contains 3 moulds of

curd). The cheese is pressed at 2 bars for 1 hour and then turned over and the same action

is repeated. A vessel is placed under the press mould to collect the expelled whey. After

pressing the cheese, the moulds are removed.

8. Salting

The purpose of salting is to inhibit: the growth and activity of food poisoning and

pathogenic micro-organisms; the activity of various enzymes in cheese; reduce the

moisture of cheese; change cheese proteins which influence cheese texture and protein

solubility; and affect cheese flavour.

Salting of cheese is carried out by filling buckets with water and salt (300g of salt/ L of

water) at 15⁰C. Place the cheese in the buckets for 10 hours in the ageing cellar and

maintain a temperature of 16⁰C to 18⁰C.

9. Maturation

Cheese maturation exposes the prepared cheese to certain environmental conditions

(temperature, humidity and so on) for several months to several years depending on the

cheese type. The purpose is to break down the proteins, lipids and carbohydrates (acids

and sugars) which releases flavour compounds and modifies cheese texture.

Remove the cheese from buckets and place on plate racks in the ageing cellar (14⁰C to

16⁰C for 24 hours). Place buckets with water in the ageing cellar in order to get

approximately 95% hygrometry (11⁰C to 14⁰C for a month). Turn the cheese over every

2 days for the 1st week and then once a week. From the 3

rd week on, brush the cheese

rind each time it is turned over.

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Product Description

Product Name Cheese Tomme

Composition Raw Milk, Starters (Sigma 41 and Omega), Rennet, Calcium

Chloride, Salt, Water

Product Characteristics Water Activity & Moisture Content (To be determined),

Usage and Consumption Who: Children, adults and old people

When: Any time of the year

How: Ready to eat

Where: Small scale distribution

Packaging To be determined

Shelf Life To be determined

Labelling Instruction Keep refrigerated

Distribution Condition Refrigerated

GMO Information No GMO in the product

Table 2: Displays the product characteristics for Tomme cheese and St. Paulin cheese.

For the production of St.Paulin cheese the production method is the same except that

the starter cultures used are different (Omega and Lambda, Sigma 96 and lota 7

respectively)

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Allergen Information

Intentional presence Non intentional presence

Cereals with gluten and products with

cereals with gluten

NO

NO

The dairy plant produces only cheese and

curd, so there is no risk of cross contamination

with other ingredients.

Crustaceans and products with crustaceans NO

Eggs and products with eggs NO

Fish and products with fish NO

Peanuts and products with peanuts NO

Soya and products with soya NO

Milk and dairy products (lactose too) YES

Fruits with shell and derived products NO

Sesame seed and products with sesame seed NO

Sulphites in concentration of 10 mg/kg

NO

Table 3: Allergen information for Tomme cheese and St.Paulin cheese.

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3.2.3 Identify intended use

It is a ready to eat product which can be consumed by the young, old, pregnant and immune-

compromised individuals.

3.2.4 Construct flow diagram

1.

Pasteurisation of raw milk (72⁰C

for 1 minute) (CCP-1 B)

Cool down to 30⁰C

Stirring (2 minutes at high speed)

Ripening (30⁰C for 2 hours)

Renneting (30⁰C for 50 minutes)

Removal of whey, cutting the

curded milk

Moulding

Pressing (P=2 Bar)

Removing cheese from moulds

Salting (Place cheese in buckets)

16⁰ C to 18⁰C for 10 hours (in the

ageing cellar)

Maturation in the ageing cellar

(CCP-4 B)

Rennet (25 mL/1000 L

of milk) (CCP-2 B)

Take pasteurized milk,

put it in a pitcher &

add Sigma 41 and

Omega respectively

(Tomme Cheese)

Take pasteurized milk, put it

in a pitcher and add Omega

and Lambda, Sigma 96 and

lota 7 respectively (St.Paulin

Cheese)

Weigh salt (300 g/L of

water (CCP-3 B)

Fill buckets with salt +

water at 15⁰C

Calcium Chloride 32 mL

Use sterilized cloth

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*The CCP’s have been identified numerically and all the CCP’s are Biological Hazards (abbreviated

as B).

Figure 1: The process flow diagram for both Tomme cheese and St. Paulin is given along with

the CCP’s determined.

3.2.5 On-site confirmation of flow diagram

The process flow diagram for cheese had already been validated and provided to us to

implement the HACCP plan.

3.2.6 List all potential hazards associated with each step, conduct a hazard

analysis, and consider any measures to control identified hazards

(SEE PRINCIPLE 1)

The hazard analysis was carried out from the receival of raw milk in cans from the milk

producer and until maturation. The possible biological, chemical and physical hazards were

determined for each step in the process and preventive measures to control the hazards were

formulated. After the analysis of the hazards, risk assessment was carried out to determine the

severity of the determined hazards. The risk assessment enables us to know how severe the

hazards are and their occurrence levels. With the knowledge of the risk assessment scores, the

potential CCP’s can be predicted and then the risks can be controlled by utilizing control points

(CP) or Critical Control Points (CCP’s) to reduce the risks.

Hazards in Ingredients & Incoming Materials Analysis Chart (Refer Annex: Chart 1)

Ingredient

and Material

Hazards Preventive Measures

Raw Milk

Receival

Biological: Bacteriological

contamination can occur if the buckets

containing milk are unclean.

PRP: Supplier and manufacturer

should use buckets which are

cleanable and which are sanitized

properly.

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Physical: Presence of foreign bodies PRP: Qualified supplier.

Chemical: Presence of antibiotics will

inhibit the growth of starter cultures

making the curd soft and floppy.

PRP: Supplier should adhere to good

herd practices.

Hazard Analysis Chart for Cheese Processing (Refer Annex: Chart 2)

Processing Step Hazards Preventive

Measures

Passage of milk through the

heat Exchanger

Biological: None

Physical: None

Chemical: Traces of cleaning and

disinfecting chemicals

PRP: Proper

sanitation

Risk Assessment

Risk = Estimation of probability

Risk Assessment: S*O

Where

S: Seriousness Index

O: Occurrence/Frequency Index

Hazards with low probability or with low severity should not be included in the HACCP

plan

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They will be managed with the PRE REQUISITE which are the Good Manufacturing

Practices (GMPs)

I. II. III.

II. III. IV.

III. IV. IV.

I. No Risk: Controlled through PRP

II. Low Risk: Controlled through GMP’s

III. Moderate Risk: Controlled through establishing CCP’s

IV. High Risk: No control measures

Risk Assessment for determined hazards (Refer Annex: Chart 3)

Processing

Step

Hazards Risk

Assessment

S F S*F

Raw Milk

Receival

Biological: Bacteriological contamination can occur if the

buckets containing milk are unclean.

2 2 III.

Physical: Presence of foreign bodies 1 2 II.

Chemical: Presence of antibiotics will inhibit the growth of

starter cultures making the curd soft and floppy.

2 1 II.

SEVERITY

FREQUENCY 1 2 3

1

2

3

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3.2.7 Determine Critical Control Points

(SEE PRINCIPLE 2)

There may be more than one CCP at which control is applied to address the same hazard. The

determination of a CCP in the HACCP system can be facilitated by the application of a decision

tree (Refer Annex: Diagram 2), which indicates a logic reasoning approach. It should be used for

guidance when determining CCPs. If a hazard has been identified at a step where control is

necessary for safety, and no control measure exists at that step, or any other, then the product or

process should be modified at that step, or at any earlier or later stage, to include a control

measure. After determining the CCP’s, it should be positioned in the flow diagram at the

appropriate step and must be identified numerically and the category of hazard that is addressed

should be précised (B for Biological, C for Chemical and P for Physical). Ex. CCP-1 B. The

CCP controls should be continuous, well specified, registered and the results must be produced

before the cheese leaves the plant.

With the aid of the decision tree four CCP’s have been established and all identified are

biological hazards which are marked in the flow diagram.

Critical Control Point determination using the decision tree (Refer Annex: Chart 4)

Processing Step Hazards Q1

(Y/N)

Q2

(Y/N)

Q3

(Y/N)

Q4

(Y/N)

Conclusion

(CCP or

not)

Raw Milk

Receival

Biological:

Bacteriological

contamination can occur

if the buckets containing

milk are unclean.

Yes No Yes Yes Not a CCP

Physical: Presence of

foreign bodies

Yes No No - Not a CCP

Chemical: Presence of

antibiotics will inhibit the

growth of starter cultures


24

making the curd soft and

floppy.

3.2.8 Establish critical limits for each CCP

(SEE PRINCIPLE 3)

Critical limits must be specified and validated for each Critical Control Point. In some cases

more than one critical limit will be elaborated at a particular step. Criteria often used include

measurements of temperature, time, moisture level, pH, Aw, available chlorine, and sensory

parameters such as visual appearance and texture. These critical limits should be measurable.

Chart displaying the critical limits for each CCP (Refer Annex, Chart 5)

HAZARD CCP CRITICAL LIMIT

Pathogenic Bacteria (Non

Sporulating)

Pasteurization (CCP-1 B) Pasteurize milk at 72⁰C for

1minute. (+/- 2⁰C)

3.2.9 Establish a monitoring system for each CCP

(SEE PRINCIPLE 4)

Monitoring is the scheduled measurement or observation of a CCP relative to its critical limits.

The monitoring procedures must be able to detect loss of control at the CCP. Further, monitoring

should ideally provide this information in time to make adjustments to ensure control of the

process to prevent violating the critical limits. Where possible, process adjustments should be

made when monitoring results indicate a trend towards loss of control at a CCP. The adjustments

should be taken before a deviation occurs. Data derived from monitoring must be evaluated by a

designated person with knowledge and authority to carry out corrective actions when indicated.

If monitoring is not continuous, then the amount or frequency of monitoring must be sufficient

to guarantee the CCP is in control. Most monitoring procedures for CCPs will need to be done

rapidly because they relate to online

Processes and there will not be time for lengthy analytical testing. Physical and chemical

Measurements are often preferred to microbiological testing because they may be done rapidly

and can often indicate the microbiological control of the product.

25

All records and documents associated with monitoring CCPs must be signed by the person(s)

doing the monitoring and by a responsible reviewing official(s) of the plant.

Chart displaying monitoring procedures to control critical limits during process (Refer

Annex: Chart 6)

CCP HAZARDS PREVENTIVE

MEASURES

CRITICAL

LIMITS

MONITORING

PROCEDURES

Pasteurization

(CCP-1 B)

Pathogenic

Bacteria (Non

Sporulating)

Pasteurize milk at 72⁰C

for 1 minute to destroy

the pathogens and

control the temperature

by using a glass

thermometer.

Ensure equipment is

adequately maintained,

correctly calibrated and

serviced every 3

months.

Pasteurize

milk at 72⁰C

for 1minute.

(+/- 2⁰C)

Who?

User

How?

Check with

another

thermomete

r

When?

During

production

3.2.10 Establish corrective actions

(SEE PRINCIPLE 5)

Specific corrective actions must be developed for each CCP in the HACCP system in order to

deal with deviations when they occur. The actions must ensure that the CCP has been brought

26

under control. Actions taken must also include proper disposition of the affected product.

Deviation and product disposition procedures must be documented in the HACCP record

keeping.

3.2.11 Establish verification procedures

(SEE PRINCIPLE 6)

Verification procedures to check the validity of the HACCP and the proper operation of the plan

would be carried out by the cheese maker during the next production run.

3.2.12 Establish Documentation and Record Keeping

(SEE PRINCIPLE 7)

To establish documentation and record keeping the support of our HACCP plan would be looked

into by the cheese maker in order to prove the product is safe, for the purpose of inspection, for

traceability, to monitor the system and is a basis for continuous improvement.

4. RECOMMENDATIONS

Hygiene Design

In the current setup at the dairy plant there is a possibility of cross-contamination as

shown in the process flow diagram as the flow of employees may cause contamination

during storage of cheese in the ageing cellar.

Since the ageing cellar is closed the frequency of cross contamination is low.

But according to the requirements of HACCP, the process flow in a building should not

overlap each other.

Hence we would like to propose to shift the tank storage rack next to the curd receiver.

And there by shifting the ageing cellar nearby salting area.

This results in a healthy process flow without any cross contamination.

STORAGE

OF MILK

HEAT

EXCHANGING

PASTEURIZATION & CHEESE

PRODUCTION

SKIMMING

RECEIVING CURD

WASHING

27

PROCESS FLOW – CURRENT SET UP

OUR PROPOSAL:

STORAGE OF

TANKS

PRESSING

ENTRANCE

Place the Storage

rack here

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5. CONCLUSION

The validated HACCP plan is a first of a kind in this plant and its effectiveness would be

checked during the next production run. On the basis of continual improvement it is always

important to have a HACCP plan and evolve from it.

The model is developed step-by-step based on the seven principles of HACCP system mentioned

in the literature review. The prerequisite program was provided to deal with some hazards before

the production; therefore, to simplify the HACCP plan. The product description was used to alert

the consumer to the potential hazards in the final products. Then, the potential control points of

the hazards appeared in both raw material and the process will be studied along with the

prevention measures. By answering the questions in the decision trees, the critical control points

were determined. Finally, the HACCP control chart was developed to include components of

several HACCP principles which are critical limits, monitoring and responsibility.

Four CCP’s were found in the production in this cheese plant. They are:

1. Pasteurization (CCP-1 B)

2. Monitoring of pH (CCP-2 B)

3. Proper dilution of salt and water; monitoring the temperature of water (CCP-3 B)

4. Monitoring of temperature and pH. (CCP-4 B)

Place ageing

cellar here

29

ANNEX

Logic Sequence for Application of HACCP (Diagram 1)

30

Hazards in Ingredients & Incoming Materials Analysis Chart (Chart 1)

Ingredient Hazards Preventive Measures

31

and

Material

Raw Milk

Receival

Biological: Bacteriological contamination

can occur if the buckets containing milk

are unclean.

PRP: Supplier and manufacturer

should use buckets which are

cleanable and which are sanitized

properly.

Physical: Presence of foreign bodies PRP: Qualified supplier.

Chemical: Presence of antibiotics will

inhibit the growth of starter cultures

making the curd soft and floppy.

PRP: Supplier should adhere to

good herd practices.

Raw Milk

Storage

Biological: Improper temperature and

time controls can lead to vegetative

pathogens and spoilage microorganisms

multiplying to levels that may be capable

of overwhelming the pasteurization

process

Store < 4⁰C for a maximum of 7 to

10 days so as to minimise the

growth of vegetative pathogens.

(When possible it is advised to use

the milk within 36 hours after

milking)

Biological: Milk is stored in tanks that, if

unclean, can result in bacterial

contamination.

PRP: Follow Pre -SSOP’s & Post-

SSOP’s

Physical: None

Chemical: Traces of cleaning and

disinfecting chemicals

PRP: Proper Sanitation

32

Starter

Cultures

Biological: Starter cultures susceptible to

strains of bacteriophages.

PRP: Qualified product supply.

Physical: None

Chemical: None

Rennet Biological: None

Physical: None

Chemical: None

Water Biological: Presence of bacteria, virus or

protozoan’s can lead to illness.

PRP: Qualified water suppliers.

Physical: None

Chemical: Presence of chlorine. (2 ppm

of chlorine will destroy 40% of rennet

activity in 3 minutes)

Test for free chlorine in water by

test strip method. (Frequency)

Salt Biological: None

Physical: Presence of foreign particles PRP: Purchase of quality product.

Chemical: None

Hazard Analysis Chart for Cheese Processing (Chart 2)

33

Processing Step Hazards Preventive Measures


heat Exchanger

Biological: None

Physical: None

Chemical: Traces of

cleaning and disinfecting

chemicals

PRP: Proper sanitation

Pasteurization Biological: Pathogenic

microorganisms (Bacillus

cereus, Listeria

monocytogens, Yersinia

enterocolitica, Salmonella

spp., Escherichia coli

O157:H7, Campylobacter

jejuni) may survive due to

improper pasteurization

temperature and control.

Pasteurize milk at 72⁰C for 1

minute to destroy the

pathogens and control the

temperature by using a glass

thermometer.

Ensure equipment is

adequately maintained,

correctly calibrated and

serviced every 3 months.

Physical: None

Chemical: Traces of


chemicals.


Stirring

Addition of Omega and

Sigma 41 starter cultures

along with Calcium

Biological: 1) Starter cultures

may act slowly due to low

temperature of milk which

results in microbiological

contamination as time

1) Genus Lactococcus &

Leuconostoc require the

temperature of milk to be 20⁰

to 40⁰ C for it to activate and

for Streptococcus

34

Chloride Solution for

Tomme Cheese production

Addition of Omega,

Lambda, Sigma 96 and lota

7 as starter culture along

with Calcium Chloride

solution for St.Paulin

Cheese production

progresses and too high a

temperature for milk may

inactivate the starter culture.

2) Incorrect quantity of

starter cultures: Too little

will allow microbiological

growth as acidity will not

develop soon enough; high

amounts will result in hard,

dry, acidic cheese.

thermophilus it is between

35⁰ to 41⁰C for it to activate.

Maintain the temperature at

35⁰C.

2) Ensure correct amount is

added.

Physical: None

Chemical: Improper

cleaning of pitchers and

stirrer may lead to

contamination of milk and

starter cultures


Ripening (2 hours) Biological: Improper action

of starter cultures on milk

due to inefficient temperature

which may allow

microbiological growth as

time progresses.

Maintain temperature of milk

in the range of 35⁰C to 40⁰C

Physical: Occurrence of

foreign bodies

Close the lid of the

pasteurization tank.

Chemical: None

35

Addition of Rennet to

pasteurized milk.

Biological: 1) Incorrect

quantity of rennet added:

Low quantities will result in

high moisture content in

cheese which will allow

microbiological growth.

High quantities will result in

the curd becoming very dry.

1) 25 ml of rennet per litre of

milk.

Biological: 2) A high pH

may allow pathogens to

recontaminate the

pasteurized milk and the

casein may not precipitate.

2) pH of 4.6 is required for

casein to precipitate.

Physical: None

Chemical: None

Removal of whey, addition

of water and cutting

Biological: Improper

handling practices leads to

contamination.

PRP: Proper personal

hygiene and handling.

Sanitize the cutters arms and

hands.

Physical: None

Chemical: Improper

sanitization of cutting tools

leads to contamination

PRP: Proper sanitization of

cutting tools.

Moulding Biological: Microbiological

contamination may occur if

the cloth and container used

for moulding is not washed

PRP: Sanitize the moulding

container and cloth.

36

properly.

Physical: None

Chemical: None

Pressing Biological: None

Physical: None

Chemical: None

Removing cheese from

moulds

Biological: Microbiological

contamination of cheese due

to unhygienic practices

PRP: GHP and GMP.

Physical: None

Chemical: None

Addition of salt (300 g/l of

water) + water into buckets

Biological: Microbial growth

due to improper dilution of

salt and water; inappropriate

temperature of water.

Add 300g of salt per litre of

water. The temperature of

water should be at 15⁰C

Physical: None

Chemical: Unclean buckets

may be a source of

contamination.


Salting (Placing the buckets

with the cheese in ageing

cellar)

Biological: Microbiological

growth due to inappropriate

temperatures.

Storage of cheese in buckets

at 16-18⁰C for 10 hours in

the ageing cellar

Physical: None

Chemical: None

37

Maturation Biological: Microbiological

contamination (yeasts and

molds) of cheese due to

improper storage conditions

and undesirable pH which

may lead to its spoilage.

Salting of cheese & proper

setting of storage conditions

(14⁰C for 1 month) to

prevent spoilage.

pH 4.1 to 4.6 is required to

control the growth of

microorganisms in cheese.

Physical: None

Chemical: None

38

Risk Assessment for determined hazards (Chart 3)

Processing Step Hazards Risk

Assessment

S F S*F

Raw Milk Receival Biological: Bacteriological contamination can

occur if the buckets containing milk are

unclean.

2 2 III.

Physical: Presence of foreign bodies 1 2 III.

Chemical: Presence of antibiotics will inhibit

the growth of starter cultures making the curd

soft and floppy.

2 1 III.

Raw Milk Storage Biological: Improper temperature and time

controls can lead to vegetative pathogens and

spoilage microorganisms multiplying to levels

that may be capable of overwhelming the

pasteurization process

3 1 III.

Biological: Milk is stored in tanks that, if

unclean, can result in bacterial contamination.

2 1 II.

Physical: None 0 0 0

Chemical: Traces of cleaning and disinfecting

substances

1 1 I.


heat exchanger

Biological: None 0 0 0



chemicals

1 1 I.

39

Pasteurization Biological: Pathogenic microorganisms

(Bacillus cereus, Listeria monocytogens,

Yersinia enterocolitica, Salmonella spp.,

Escherichia coli O157:H7, Campylobacter

jejuni) may survive due to improper

pasteurization temperature and control.

3 1 III.



chemicals in pasteurization tank.

1 1 I.

Stirring

Addition of Omega and Sigma

41 starter cultures along with

Calcium Chloride Solution for

Tomme Cheese production

Addition of Omega, Lambda,

Sigma 96 and lota 7 as starter

culture along with Calcium

Chloride solution for St.Paulin

Cheese production

Biological: 1) Starter cultures may act slowly

due to low temperature of milk which results

in microbiological contamination as time

progresses and too high a temperature for milk

may inactivate the starter culture.

3 1 III.

Biological: 2) Incorrect quantity of starter

cultures: Too little will allow microbiological

growth as acidity will not develop soon

enough; high amounts will result in hard, dry,

acidic cheese.

3 1 III.


Chemical: Improper cleaning of pitchers and

stirrer may lead to contamination of milk and

starter cultures

1 1 I.

40

Ripening (2 hours) Biological: Improper action of starter cultures

on milk due to inefficient temperature which

may allow microbiological growth as time

progresses.

3 1 III.

Physical: Occurrence of foreign bodies 2 1 II.

Chemical: None 0 0 0

Addition of Rennet to

pasteurized milk.

Biological: 1) Incorrect quantity of rennet

added: Low quantities will result in high

moisture content in cheese which will allow

microbiological growth.

High quantities will result in the curd

becoming very dry.

3 1 III.

Biological: 2) A high pH may allow pathogens

to recontaminate the pasteurized milk and the

casein may not precipitate.

3 1 III.



Removal of whey, addition of

water and cutting

Biological: Improper handling practices leads

to contamination.

2 1 II.


Chemical: Improper sanitization of cutting

tools leads to contamination

2 1 II.

Moulding Biological: Microbiological contamination

may occur if the cloth and container used for

moulding is not sterilized properly.

2 1 II.

41



Pressing Biological: None 0 0 0



Removing cheese from moulds Biological: Microbiological contamination of

cheese due to unhygienic practices

3 1 III.



Addition of salt (300 g/l of

water) + water into buckets

Biological: Microbial growth due to improper

dilution of salt and water; inappropriate

temperature of water.

2 1 II.


Chemical: Unclean buckets may be a source

of contamination.

2 1 II.

Salting (Placing the buckets

with the cheese in ageing

cellar)

Biological: Microbiological growth due to

inappropriate temperatures.

3 1 III.



Maturation Biological: Microbiological contamination

(yeasts and molds) of cheese due to improper

storage conditions and undesirable pH which


3 1 III.


42


HACCP Decision tree utilized to determine the critical control points (Diagram 2)

43

Critical Control Point determination using the decision tree (Chart 4)

Processing Step Hazards Q1

(Y/N)

Q2

(Y/N)

Q3

(Y/N)

Q4

(Y/N)

Conclusion

(CCP or

not)

Raw Milk

Receival

Biological:

Bacteriological

contamination can occur

if the buckets containing

milk are unclean.


Physical: Presence of

foreign bodies


Chemical: Presence of

antibiotics will inhibit the

growth of starter cultures

making the curd soft and

floppy.


Raw Milk

Storage


temperature and time

controls can lead to

vegetative pathogens and

spoilage microorganisms

multiplying to levels that

may be capable of

overwhelming the

pasteurization process


Biological: Milk is stored Yes No Yes Yes Not a CCP

44

in tanks that, if unclean,

can result in bacterial

contamination.

Chemical: Traces of


materials


Passage of milk

through the heat

Exchanger

Biological: None - - - - -

Physical: None - - - - -

Chemical: Traces of


chemicals


Biological: Pathogenic

microorganisms (Bacillus

cereus, Listeria

monocytogens, Yersinia

enterocolitica, Salmonella

spp., Escherichia coli

O157:H7, Campylobacter

jejuni) may survive due to

improper pasteurization

temperature and control.

Yes Yes - - CCP


Chemical: Traces of


chemicals in

pasteurization tank.


45

Stirring

Addition of

Omega and

Sigma 41 starter

cultures along

with Calcium

Chloride

Solution for

Tomme Cheese

production

Addition of

Omega, Lambda,

Sigma 96 and

lota 7 as starter

culture along

with Calcium

Chloride solution

for St.Paulin

Cheese

production

Biological: 1) Starter

cultures may act slowly

due to low temperature of

milk which results in

microbiological

contamination as time

progresses and too high a

temperature for milk may

inactivate the starter

culture.



quantity of starter

cultures: Too little will

allow microbiological

growth as acidity will not

develop soon enough;

high amounts will result

in hard, dry, acidic

cheese.


Chemical: Improper

cleaning of pitchers and

stirrer may lead to

contamination of milk and

starter cultures


Ripening (2

hours)


action of starter cultures

on milk due to inefficient

temperature which may


46


growth as time

progresses.

Physical: Occurrence of

foreign bodies


Chemical: None - - - - -

Addition of

Rennet to

pasteurized milk.


quantity of rennet added:

Low quantities will result

in high moisture content

in cheese which will


growth.

High quantities will result

in the curd becoming very

dry.


Biological: A high pH

may allow pathogens to

recontaminate the

pasteurized milk and the

casein may not

precipitate.

Yes Yes - - CCP



Removal of whey,

addition of water

and cutting


handling practices leads to

contamination.


47


Chemical: Improper

sanitization of cutting

tools leads to

contamination


Moulding Biological:

Microbiological

contamination may occur

if the cloth and container

used for moulding is not

sterilized properly.




Pressing Biological: None - - - - -



Removing cheese

from moulds

Biological: None - - - - -

Physical: Contamination

of cheese due to

unhygienic practices



Addition of salt

(300 g/l of water)

+ water into

buckets

Biological: Microbial

growth due to improper

dilution of salt and water;

inappropriate temperature

of water.

Yes Yes - - CCP

48


Chemical: Unclean

buckets may be a source

of contamination.


Salting (Placing

the buckets with

the cheese in

ageing cellar)

Biological:

Microbiological growth

due to inappropriate

temperatures.




Maturation Biological:

Microbiological

contamination (yeasts and

molds) of cheese due to

improper storage

conditions and

undesirable pH which


Yes Yes - - CCP



49

Chart displaying the critical limits for each CCP (Refer Annex, Chart 5)

HAZARD CCP CRITICAL LIMIT

Pathogenic Bacteria (Non

Sporulating)

Pasteurization (CCP-1 B) Pasteurize milk at 72⁰C for

1minute. (+/- 2⁰C)

Microbiological

Contamination of pasteurized

milk during the action of

rennet on milk

Monitoring of pH (CCP-2 B) The pH should be at 4.6 (+/-

2) for the casein to precipitate

and to prevent microbial

growth.

Microbiological growth due to

improper dilution of salt and

water during salting.

Proper dilution of salt and

water; monitoring the

temperature of water (CCP-3

B)

300g of salt per litre of water,

temperature of water should

be at 15⁰C (+/- 2⁰C)

Microbial contamination due

to inappropriate temperature

and pH during maturation

Monitoring of temperature and

pH. (CCP-4 B)

Store at 14⁰C for 1 month,

pH 4.1 to 4.6 is required.

50

Chart displaying monitoring procedures to control critical limits during process (Chart 6)

CCP HAZARDS PREVENTIVE

MEASURES

CRITICAL

LIMITS

MONITORING

PROCEDURES

Pasteurization

(CCP-1 B)

Pathogenic

Bacteria (Non

Sporulating)

Pasteurize milk

at 72⁰C for 1

minute to

destroy the

pathogens and

control the

temperature by

using a glass

thermometer.

Ensure

equipment is

adequately

maintained,

correctly

calibrated and

serviced every 3

months.

Pasteurize

milk at 72⁰C

for 1minute.

(+/- 2⁰C)

Who?

User

How?

Check with another

thermometer

When?

During production

Monitoring of

pH (CCP-2 B)

Microbiological

Contamination

of pasteurized

milk during the

action of rennet

on milk

pH of 4.6 is

required to

prevent

microbial

contamination

and for the

casein to

precipitate.

The pH

should be at

4.6 (+/- 2)

for the

casein to

precipitate

and to

prevent

microbial

growth.

Who?

User

How?

Check the pH of

whey with a pH

meter.

When?

Before the curd is

cut.

Proper

dilution of

salt and

water;

monitoring

Microbiological

growth due to

improper

dilution of salt

and water

Add 300g of salt

per litre of

water. The

temperature of

water should be

300g of salt

per litre of

water,

temperature

Who?

Person incharge.

How?

Microbiological

analysis of water

51

the

temperature

of

water(CCP-3

B)

during salting. at 15⁰C of water

should be at

15⁰C (+/-

2⁰C)

When?

Once in a year (or

during uncertainty)

Monitoring of

temperature

and pH.

(CCP-4 B)

Microbial

contamination

due to

inappropriate

temperature and

pH during

maturation

Salting of

cheese & proper

setting of

storage

conditions

(14⁰C for 1

month) to

prevent

spoilage.

pH 4.1 to 4.6 is

required to

control the

growth of

microorganisms

in cheese.

Store at

14⁰C for 1

month,

pH 4.1 to

4.6 is

required.

Who?

The producer

How?

With the

thermometer and

pH meter.

When?

Every two weeks.

52

6. BIBLIOGRAPHY

http://www.codexalimentarius.net/search/advancedsearch.do (RECOMMENDED

INTERNATIONAL CODE OF PRACTICE, GENERAL PRINCIPLES OF FOOD

HYGIENE, CAC/RCP 1-1969, Rev. 4-2003)

http://www.geladairy.com/DAIRYMAGH.htm (Spoilage and Pathogenic

Microorganisms in Milk)

http://www.raw-milk-facts.com/Raw_Milk_FAQ.html (How long can raw milk keep?)

http://www.renconz.com/renco_Rennet.cfm (Action of rennet in cheese making)

http://www.ces.ncsu.edu/depts/foodsci/ext/pubs/antibioticresidues.html (Preventing

antibiotic residues in milk)

http://www.cfsan.fda.gov/~ear/daihaz.html (Hazards and Controls Guide For Dairy

Foods HACCP, Guidance for Processors, Version 1.1 June 16, 2006)

http://www.pubmedcentral.nih.gov/articlerender.fcgi?artid=535134 (Milk Contamination

and Resistance to Processing Conditions Determine the Fate of Lactococcus lactis

Bacteriophages in Dairies)

http://www.specialistcheesemakers.co.uk/best_practice/Cheesemaking.htm (The

Specialist Cheesemakers Code of Best Practice, Identifying hazards in the processing

chain)

http://www.microbeworld.org/news/water_quality/news_water_quality_01.aspx

(Microbiological contaminants in water)

http://www.codexalimentarius.net/search/advancedsearch.do

http://www.geladairy.com/DAIRYMAGH.htm

http://www.raw-milk-facts.com/Raw_Milk_FAQ.html

http://www.renconz.com/renco_Rennet.cfm

http://www.ces.ncsu.edu/depts/foodsci/ext/pubs/antibioticresidues.html

http://www.cfsan.fda.gov/~ear/daihaz.html

http://www.pubmedcentral.nih.gov/articlerender.fcgi?artid=535134

http://www.specialistcheesemakers.co.uk/best_practice/Cheesemaking.htm

http://www.microbeworld.org/news/water_quality/news_water_quality_01.aspx

53

http://findarticles.com/p/articles/mi_m3301/is_1_107/ai_n16030263 (Starter Cultures &

pH for casein precipitation)

http://www.foodsci.uoguelph.ca/dairyedu/micro.html#micro1 (Pathogenic

microorganisms, 11/11/08)

http://www.milkproduction.com/Library/article_series/idf_fao_symp/Microbiological_ha

zards_that_need_to_be_managed_during_and_after_processing.htm (Pathogenic and

spoilage microorganisms, 11/11/08)

Microbiology, Fourth Edition, Philip L. Carpenter, Professor Emeritus of Microbiology,

University of Rhode Island, and Pages Referred 300-325, 454-475

Food Safety Management, Part 1 to V-Global Context, Tanguy Bantas (t.bantas@isa-

lille.fr)

http://findarticles.com/p/articles/mi_m3301/is_1_107/ai_n16030263

http://www.foodsci.uoguelph.ca/dairyedu/micro.html#micro1

http://www.milkproduction.com/Library/article_series/idf_fao_symp/Microbiological_hazards_that_need_to_be_managed_during_and_after_processing.htm

http://www.milkproduction.com/Library/article_series/idf_fao_symp/Microbiological_hazards_that_need_to_be_managed_during_and_after_processing.htm

mailto:[email protected]

mailto:[email protected]

39197964 haccp plan dairy plant isa

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