The Food Safety Plan H.A.C.C.

P
Terms of reference:

This linear HACCP plan covers the manufacture of an apple yogurt product, packaged in a pot.
It will start at raw materials intake through to dispatch of processing plant.
The HACCP plan will cover final product safety and will look at the following hazards:

Physical Glass and hard brittle plastic
Metal

Chemical Pesticide residues in fruit
Chemical residues associated with the packaging materials
Chemical residues associated with cleaning

Biological Unwanted bacteria yogurt, raw milk and fruit.

The company has in place a number of effective prerequisite programs including:
Cleaning and Sanitising
Pest Control
Personal Hygiene Requirements
Staff Training

The company complies with the following acts of legislation
Regulation (EC) No 178/2002 of the European Parliament and of the Council
Regulation (EC) No 852/2004 of the European Parliament and of the Council

And the following codes of practice/guidelines documents were used in developing this
HACCP plan:
Campden BRI HACCP: A Practical Guide (Fourth edition). Guideline No 42
British Retail Consortium Global Standard for Food Safety (Issue 6)
Department of Health Guidelines for the Safe Production of Heat Preserved Foods
Institute of Food Science and Technology Food & Drink Good Manufacturing Practice, A
Guide to its Responsible Management.
Codex Alimentarius Food Hygien Basic Texts (Third Edition)
1.1 The HACCP food safety team
1.1.1
The HACCP plan is developed and managed by Fab Foods multi-disciplinary food safety team
which includes those responsible for quality/technical, production operations, engineering and
other relevant functions.
The team leader has an in-depth knowledge of HACCP and is able to demonstrate competence
and experience.
The team members have specific knowledge of HACCP and relevant knowledge of product,
process and associated hazards.
In the event of the company not having appropriate in-house knowledge, external expertise will
used, but day-to-day management of the food safety system remains the responsibility of the
company.
HACCP Team Member Responsibility
Quality Assurance Carries out systematic measurements,
comparison with BRC standard, monitoring
of processes and an aims to prevent error.
Quality Control Reviews the quality of all factors involved in
production with focus on process outputs.
Production Specialist contribute details of what actually happens
on the production line
throughout all shift patterns
Engineer Provides information on the operating
characteristics of the process
equipment under study and the hygienic
design of equipment and buildings
Microbiologist Understands the microbiological hazards and
risks associated with the product.
Others Including; specialist equipment operators,
hygiene manager, ingredient and packaging
buyers, distribution manager, maintenance
and calibration operators.
External HACCP Members If knowledge is not available in-company,
consultation with an eternal resource will be
carried out.
Table 1: Breakdown of Fab Foods HACCP Team and Responsibilities.

All persons are trained in HACCP and repeat the training annually.
Below is a table showing how Fab Foods operates an organised structure of the HACCP team.

Table 2: Fab Foods operation of an organised structure of the HACCP team.





1.2 Prerequisite programmes
1.2.1
Fab Foods has established and maintains environmental and operational programmes necessary
to keep an environment suitable to produce safe and legal food products
Prerequisite programmes include:
Cleaning and Sanitising
Pest Control
Personal Hygiene Requirements
Staff Training


Process
Step

Hazard

Prevention

Control
Limits
Monitor
Method
Monitor
Frequency

Record
Sheet
Person
Responsi
ble

Corrective
action


Validation
ENVIRONMENTAL HYGIENE

Environ
mental
Hygiene

Presence
of listeria/
Salmonell
a


Environm
ent swabs

Listeria/sa
lmonella
absent

ISO
approved
methods

Weekly
monthly/
Quarterly


Pathogen
file


QC
Manager
Full
investigati
on, re
clean and
re swab
area


Weekly
review of
pathogen
file by QC
HYGIENIC HANDLING OF INGREDIENTS
* Milk,
* Starter
Cultures
(S.thermo
philus&
L.burglari
ous)
* Fruit
(diced
apples)
*Stabiliser
(pectin)
* Flavour
Enhancers
Presence
of
pathogeni
c
microorga
nisms


Pathogen
screening


Below
pathogen
limits
SOP
Testing
procedure
for
investigati
on of
pathogens



Weekly

Pathogen
screening
monitorin
g sheet


QC
Manager
In case of
pathogen
presence
immediate
rejection
of
product.
Presence
of
pathogeni
c
microorga
nisms
CLEANING, MAINTENANCE & PERSONNEL HYGIENE AT PRIMARY PRODUCTION
Cleaning,
Maintena
nce &
Personnel
Hygiene
at
Primary
Productio
n



Physical
/Micro
contamina
tion



Cleaning
procedure
s



Clean
areas,
swab
enterobact
eria <10




Hygiene
inspection
, swabs





Weekly


Hygiene
records
Cleaning
records
Maintenan
ce records




Technical
Manager
Areas not
cleaned
correctly,
revisit
areas with
operator,
reclean
and
reswab



Weekly
review of
hygiene
cleaning
and
maintenan
ce
LOCATION


Location
of
Factory


Cross
contamina
tion


Productio
n area
segregated



Segregate
d area



Visual



NA



NA



Technical
Productio
n areas
must be
segregated
, if this is
violated,
investigat
e reason


Internal
and
external
audits

PREMISES
Design,
layout,
Internal
Structure
s &
Fittings

Physical
/Micro
contamina
tion

Food
grade
walls and
equipment

Clean &
undamage
d
Visual and
Hygiene
and
housekeep
ing audits


Ongoing.
Hygiene
and
Housekee
ping
Audits


Technical
Action log
created.
Actions
monitored
continuou
sly

Internal
and
external
audits
EQUIPMENT
Food
Control
&
Monitori
ng
Equipme
nt



Physical
/Micro
contamina
tion



Audit/Vis
ual
Inspection



Clean &
undamage
d



Visual and
Hygiene
and
housekeep
ing audits



Ongoing.


Hygiene
and
Housekee
ping
Audits




QC
manager
Hygiene
and
household
records
created.
Continuou
s
monitorin
g.



Internal
and
external
audits
Containe
rs For
Waste &
Inedible
Substanc
es
Physical
/Micro
contamina
tion
Clean
colour
coded
waste
containers
Correct
colour,
clean and
undamage
d
Visual and
Hygiene
and
housekeep
ing audits


Clean
daily
Hygiene
and
Housekee
ping
Audits


Productio
n

Monitorin
g log
created.

Daily
monitorin
g of waste
containers
FACILITIES
Water
Storage
Legionella
contamina
tion
Legionella
testing
Absent
External
company
sample
and test
All areas
at least
twice
annually
Water
storage
records
Quality
Control
Officer
Investigat
e if
legionella
found in
water, risk
access
product
Legionella
file
Personal
Hygiene/c
aptive
clothing
Physical
/Micro
contamina
tion
Hand
washing/c
aptive
clothing
Correct
hand
washing
procedure
s and
change of
clothing in
productio
n areas
Visual
hand
swabs,
and
Hygiene
and
housekeep
ing audits
On-
going/qua
rterly
Hygiene
records
All
Employee
s
Report
deviations
to
supervisor
/manager
Action log
Temperat
ure
Control
Product
contamina
tion
Temperat
ure
monitorin
g
Temperat
ure
specificati
ons
Calibrated
thermome
ters
As per
schedules
Temperat
ure
Records
QC
manager
Report
deviations
to QC
manager
Weekly
audit of
temperatu
re records
CLEANING MANAGEMENT



Cleaning
Program
mes


Contamin
ation due
to
ineffective
hygiene
procedure
Spray
with
acidic
solution
after clean
on filler
inside
surfaces



Surface
hygiene
tests



Surface
hygiene
tests



After each
cleaning
cycle




Cleaning
logs



Productio
n
operators
Do not
proceed
with
productio
n until
satisfactor
y hygiene
has been
achieved
Weekly
review of
cleaning
logs.

Internal/e
xternal
audits
Cleaning
Program
mes
Contamin
ation due
to
ineffective
hygiene
procedure
CIP and
hand
cleaning
procedure
s
Cleaning
carried out
to correct
time,
temperatu
re and
sanitizer
strength
Visual
inspection
s, sanitizer
checks
and
swabbing
regimes
As per
cleaning
scheduled/
frequencie
s
Cleaning
logs
Operators/
Team
leaders/Te
chnical
Do not
proceed
with
productio
n until
satisfactor
y plant
hygiene
has been
achieved.
Weekly
review of
cleaning
logs.

Internal/e
xternal
audits
PEST CONTROL SYSTEMS




Pest
Control


Microbiol
ogical,
Physical
or
chemical
risks
associated
with pests.




Pestguard
Plus
contract in
place with
Rentokil



All
evidence
of pest
activity
reported
and
controlled.




Pest
Control
Technicia
n



Pest
control
technician
-monthly
visits





Rentokil
File
reports.





Technical
Manager
All pest
control
actions &
corrective
actions
taken
reported
to
technical
manager.





Rentokil
report.
WASTE MANAGEMENT







Waste
Managem
ent





Rubbish
provides
environme
nt for pest
harborage.





Rubbish
cleared on
a regular
and
routine
basis.






All
rubbish to
be
removed.





Hygiene
&
Housekee
ping Audit
schedule
in place.







Once per
month
Waste
transportat
ion
document
ation
Any
reports of
visual
sightings
of
waste/deb
ris in the
productio
n area or
surroundi
ng areas.







Waste
coordinati
ng officer





Action log
created
and issued
to
Technical
Manager






Waste
document
ation file.
PERSONAL CLEANLINESS







Hygiene
Policy











Non-
complianc
e with
general
hygiene
practises
Fully
document
ed
Hygiene
Code of
Practice
compiled
from
Customer
Codes of
Practice
and Good
Manufact
uring
Practices.






100%
complianc
e by all
site
personnel.






Hygiene
&
Housekee
ping Audit
schedule
in place.







Quarterly







Hygiene
records







Technical
Manager

Action log
created
and issued
to General
Manager






Hygiene
and
Housekee
ping audit


Personnel
hand
swabbing
regime in
place for
productio
n area.




Monthly



Hygiene
records



Technical
manager



Re swab
and if
positive
discuss
hygiene
policy
with the
operator



Hygiene
and
Housekee
ping audit






Visitors


Visitors
not aware
of the site
hygiene
requireme
nts.
Unfit/unw
ell visitors
enter site.
Rules for
Visitors
Procedure
in place.
Sign in at
reception.
Sign in
agreement
to follow
company
rules
while on
site.




No unfit
visitors
allowed in
high risk
areas of
factory.






Hygiene
rules






Each
visitor.






Visitors
Book






Reception
ist


Vistors
must meet
the correct
safety
citeria to
be
allowed
access to
the
premise





Annual
audit of
visitor
records

Table 3: Fab Foods Prerequisite Process.








Cleaning and Sanitising

The order of operation for cleaning/sanitizing of food product contact surfaces is
Rinse
Clean
Rinse
Sanitize.

The company uses a number of types of cleaning.

Mechanical Cleaning. Often referred to as clean-in-place (CIP). Requires no disassembly or
partial disassembly.
Clean-out-of-Place (COP). Can be partially disassembled and cleaned in specialized COP
pressure tanks.
Manual Cleaning. Requires total disassembly for cleaning and inspection.

Following cleaning, sanitization is completed, types include;
Thermal Sanitization involving the use of hot water or steam for a specified temperature and
contact time.
Chemical Sanitization involving the use of an approved chemical sanitizer at a specified
concentration and contact time.

Cleaning and Sanitization is carried out to remove unwanted matter on food-contact surface,
referred to as Food Soil.
Detergents and cleaning compounds are composed of mixtures of ingredients that interact with
soils in several ways: Physically active ingredients alter physical characteristics such as
solubility or colloidal stability. Chemically active ingredients modify soil components to make
them more soluble and, thus, easier to remove. Example of cleaning agents used are Alkaline
Builders, Acid Builders, Water Conditioners, Oxidizing Agents, and Enzyme-based detergents.
The below table is used when selecting cleaning agent to use.
Surface Deposit Cleaning Solubility
Sugar Water soluble
Fat Alkali soluble
Protein Alkali soluble
Starch Water soluble, Alkali soluble
Monovalent Salts Water soluble; Acid soluble

Table 4: Surface Deposit vs. the Cleaning Solubility


















Examples of sanitizers include; Chlorine, Iodophors, Quarternary ammonium compounds,
Acid anionic, Fatty Acid, Peroxyacetic acid
The below table can be used when selecting cleaning agent to use

Chlorine

Iodophors
Quarternary
ammonium
compounds

Acid anionic
Fatty
Acid
Peroxyacetic
acid
Corrosive Corrosive Slightly
corrosive
Noncorrosive Slightly
corrosive
Slightly
corrosive
Slightly
corrosive
I rritating to skin Irritating Not
irritating
Not irritating Slightly
irritating
Slightly
irritating
Not irritating
Effective at
neutral pH
Yes Depends
on type
In most cases No No Yes
Effective at acid
pH
Yes, but
unstable

Yes
In some
cases
Yes, below
3.0-3.5
Yes,
below 3.5-
4.0
Yes

Effective at
alkaline pH
Yes, but
less than
at neutral
pH

No

In most cases

No

No

Less
effective
Affected by
organic material
Yes Moderately Moderately Moderately Partically Partially
Affected by
water hardness
No Slightly Yes Slightly Slightly Slightly
Residual
antimicrobial
activity

None

Moderate

Yes

Yes

Yes

None
Cost Low High Moderate Moderate Moderate Moderate


I ncompatibilities
Acid
solutions,
phenols,
amines
Highly
alkaline
detergents
Anionic
wetting
agents,
soaps, and
acids
Cationic
surfactants
and alkaline
detergents
Cationic
surfactants
and
alkaline
detergents
Reducing
agents, metal
ions, strong
alkalies
Stability of use
solution
Dissipates
rapidly
Dissipates
slowly
Stable Stable Stable Dissipates
slowly
Maximum level
permitted by
FDA without
rinse


200ppm


25ppm


200ppm


Varied


Varied


100-200ppm
Water
temperature
sensitivity

None

High

Moderate

Moderate
Moderate None
Foam level None Low Moderate Low/Moderate Low None
Phosphate None High None High Moderate None
Soil load
tolerance
None Low High Low Low Low

Table 5: Comparison of the Chemical and Physical Properties in commonly used Sanitizers
It is important that the clean, sanitized equipment and surfaces drain dry and are stored dry so
as to prevent bacteria growth. Necessary equipment must also be cleaned and stored in a clean,
sanitary manner.
Cleaning/sanitizing procedures are evaluated for adequacy through evaluation and inspection
procedures. Adherence to prescribed written procedures (inspection, swab testing, direct
observation of personnel) are continuously monitored, and records maintained to evaluate long-
term compliance.
(Schmidt, 2000)
All areas regarding Cleaning and Sanitizing must be documented and signed in appropriate
specification sheets.
















Pest Control
Pest Control is carried out to eliminate the entry of insects and rodents into the food processing
premises.
Pests include: Rodents (Rats, Squirrels, Mice etc.) Cockroaches, Flies, Ant, Birds and other
vertebrates.
Control of Pests in done by an outside service provided by Rentokil. (Hazel House, Millennium
Park, Naas, Co Kildare, 1890 333 888).
Poisoned Bait, Traps, Electrical Discharge system, Repellents, Pitfall traps and Sticky insect
traps are among the controls put in place by Rentokil.
In addition to this:
The exterior of the premises is well-maintained by designated maintenance staff, lawns
are mowed once a week and any debris which could be a possible nesting place for
rodents/insects are removed. Evidence of pests such as dropping are examined for.
The interior and exterior of processing plant is inspected twice weekly to ensure that no
pests have begun to congregate.
Pest control is included on the factory daily schedule.
Drains onsite are fitted with rodent traps.
All entrances to the factory are effectively concealed from pests when closed.
In the event that a pest is found on the premises immediate action must be taken.
Incident should be immediately reported to supervisor. Product recall may be necessary.
All areas regarding Pest Control must be documented and signed in appropriate
specification sheets.








Personal Hygiene Requirements / Staff Training
The below house rules are in place as well and in conjunction with H.A.C.C.P. Staff are
trained upon entry and annually by an official body which comply with the FSAIs Guide to
Food Safety Training Level 1 and Level 2.
Prerequisite Control Measure
All staff in contact with food items must
confirm they are free of disease before they
are employed.
Require new staff members to complete a
questionnaire about their medical situation
and/or arrange for them to be tested for
infectious diseases.

All staff in contact with food items must
wear protective clothing.
Clean white cotton/polyester overalls or
coats for all staff in contact with
unpackaged food are provided and dry
cleaned.

Staff are prohibited staff who are
experiencing vomiting or diarrhoea or have
infected wounds on their hands or lower
arms from handling unpackaged food items.
If a person has these symptoms either send
them home until they are better or move
them to an area when they do not handle
unpackaged food items. Provide adhesive
medical dressings for staff to put over any
wounds, cuts or abrasions on hands or lower
arms
Ensure that staff put on disposable hair nets,
and beard nets (where applicable) before
putting on their protective clothing.
It is company policy to arrange for staff to
be inducted and trained to do this.



Use gloves that are fit for purpose.
Glove sizes are available to take into
account the different sized hands/ The
gloves should be tight fitting but not so tight
as to be uncomfortable. Disposable gloves
have are designed for use with food. For
tasks such as cleaning or pest control use
rubber, non-disposable, thick gloves.

Staff must remove protective clothing
before going to the toilet.
The facility is designed so staff must outer
layer of protective clothing - prior to going
to the toilet. This will include installing
hooks on which to hang the clothes coming
off.
Provide facilities for staff to store outdoor
clothes and personal effects.
Install lockable cabinets in the changing
facility.
Staff must to wash hands regularly
especially after bathroom, food or smoke
breaks; after handling waste or uncooked
food items and after sneezing or touching
their faces.

Signs are placed in bathrooms and in
entrances to the processing areas
reminding people to wash their hands

Eating, drinking or chewing of gum in food
processing areas is prohibited.
It is policy that eating, drinking or chewing
of gum in food processing areas is
prohibited. A canteen is provided for such
activities.


Staff should not sneeze over food items.
Staff are trained to turn away and sneeze
into the crook of their arm or into hands
over their face. Afterwards they should
blow their nose with tissues & wash their
hands

Wearing of any jewellery in food
processing areas is prohibited. This
includes watches, ring, earrings, necklaces
bracelets and hairpieces.
All staff must sign a declaration saying they
will abide by this policy.
Visitors are asked to remove jewellery.
Signs to doorways leading into processing
areas remind people they should remove
jewellery.
Table 6: Personal Hygiene Requirements / Staff Training & Control Measures.

1.3 Description of the product
1.3.1
The scope of each HACCP plan, includes the products and processes covered, including
Composition, e.g. raw materials, ingredients, allergens, recipe
Origin of ingredients
Physical or chemical properties that impact food safety, e.g. pH, aw
Treatment and processing, e.g. cooking, cooling
Packaging system, e.g. modified atmosphere, vacuum
Storage and distribution conditions, e.g. chilled, ambient
Target safe shelf life under prescribed storage and usage conditions
Instructions for use, and potential for known customer misuse, e.g. storage, preparation.

Process/Product type: Yogurt
Product name: Absolutely Apple
Composition:

Skim milk, skim milk powder, apple fruit,
preservatives, bacterial cultures (
Important product characteristics aw, pH, preservatives, processing
How it is to be used: Direct consumption
Packaging: Plastic cup and foil sealed
Shelf life: 2 weeks
Where it will be sold: Retailers
Labelling instructions: Within legal limits, as per BRC standards.
Special storage and distribution control: Refrigerated at < 5C

Table 7: Product Description


1.3.2
Fab Foods ensures that the HACCP plan is based on comprehensive information sources, which
are referenced and available on request. It uses:
the latest scientific literatures
historical & known hazards associated with specific food products relevant codes of
practice
recognized guidelines
food safety legislation relevant for the production and sale of products
customer requirements.

1.4 Identified intended use
1.4.1
The intended use of the product by the customer is described, defining the consume target
groups, including the suitability of the product for vulnerable groups of the population (e.g.
infants, elderly, allergy sufferers).

1.5 Construction a process flow diagram
1.5.1
The prepared flow diagram covers each product, product category or process. This sets out all
aspects of the food process operation within the HACCP scope, from raw material receipt
through to processing, storage and distribution. It contains the following:
plan of premises and equipment layout
raw materials including introduction of utilities & other contact materials, e.g water,
packaging
sequence and interaction of all process steps
outsourced processes and subcontracted work
process parameters
potential for process delay
rework and recycling
low/high-care/high-risk area segregation
finished products, intermediate/semi-processed products, by-products and waste.
Path of
Milk
CCP 1
Divert of Product
where applicable
2. Mixing Hopper
12. Holding of yogurt in
holding tanks
21. Cold Storage,<5C 22. Dispatch
18. Blast Chilled
20.Trayed/palletised
6a. Preheating of Milk in
Pasteuriser
6c. De-aeration
6b. Homogenisation
17. Metal Detection
3b Incoming
Packaging/ingredients
9. Cutting of yogurt ph
4.6
1.Organic Milk Storage Silo 6,7,8
4. Filtration
8. Incubation 36-43C
Waste Milk to Effluent
10.Filtration 0.5mm
11. Cooled 25 -30C
3. Addition of dry
Ingredients (SMP,
NaC) fromambient
storage
7. Inoculation
- addition of
Cultures from
freezer
Packaging
in
warehouse
13. Fruit
addition from
ambient
storage
15a. Lid
& pot
deboxing
19. Sleeves &
trays
packaging
5. Pumping of milk
through balance tank
6d.Pasteurisation
93 C x 4min
14. Addition &
mixing of fruit &
yogurt
16.Filling, sealing &
dating of yogurt pots
15b.Pot & lid
packaging
Waste yog to
effluent plant &
packaging to
recycling/skip

Unit Operations
Milk storage Silo
When the milk is received after passing quality testing. The milk is pumped from the tanker to
the milk storage silos. Here the milk should be stored at <7C and held for no longer than 72
hours. Silos are agitated to make sure that the entire volume remains cold and that the milk fat
does not separate from the milk. When the silo is empty, it is Cleaned In place with specific
agents before the next milk from tankers are received.

Mixing Hopper
Milk from the silo is then passed in to the mixing hopper, where ingredients which were stored
at ambient temperature, such as calcium and vitamins are added to the milk to be enriched. It
provides gentle agitated to distribute the ingredients to form a precise liquid. It provides cooling
so the milk stays under 7C.

Filtration
The type of filtration technology used in the industry is Microfiltration which is a low pressure-
driven membrane filtration process, which is based on a membrane with an open structure
allowing dissolved components to pass while most non-dissolved components are rejected by
the membrane. In the dairy industry, microfiltration here which is used for bacteria reduction
and fat removal in milk and whey as well as for protein and casein standardisation. The size of
the membrane is 1.4m.
This is an essential process step to protect flavour, ensure nutritional value, and prevent
microbial or physical contamination. It allows a product to have a specified fat content and for
total fat and solids content.
The type of membrane used in this filtration system is ceramic. They are resistant to
temperature, chemicals and are easy to clean.

Balance tank

The milk is then pumped in to a balance tank or float tank. The tank is equipped with a float
valve. The purpose of this is to keep the milk at a constant level and to maintain a constant
supply of milk to the regeneration section of the pasteuriser.
Pasteurisation
Milk which is still at 4C is pumped from the balance tank into the regeneration section of the
plate heat exchanger, where it is heated. The plate heat exchanger contains a series of stainless
steel plates stacked together with spaces in between them. The spaces are the forming chambers
which hold the milk as it passes through.

The milk will increase from 4C to 72C for effective pasteurisation. This is held for 15 seconds
and then chilled again to 4C.

In the regeneration section the heat of the pasteurised milk is used to warm up the cold milk.
Therefore the outgoing hot milk is the heating medium for the cold raw milk. The cold milk is
the cooling medium for the hot milk, as it is used to cool down the hot milk from 72C to 4C.
This all takes place in the plate heat exchanger where counter current flow is the most effective
way of heat exchange. When the cold milk meets the oncoming hot milk, and is heated up, it
is then passed through the holding tube which is long enough to last at least 15 seconds. Here
the milk is being pasteurised. It flows to the regeneration section where it warms up the cool
milk coming in and then off to the cooling section which is the final section.

The divert valve on the processing unit is used for diversion of any liquid that may be under
the pasteurisation temperature. In this case if its under 72C the milk is brought back to the
regeneration section and pasteurised again.

Pasteurisation is a thermal processing technique whereby milk is exposed to a
time / temperature combination of 72C for 15 seconds. This will make the product safe for
human consumption. Pasteurisation does not affect chemical, physical or organoleptic
characteristics of the milk. The primary function of pasteurisation is a food safety function.
However, as well as destroying pathogenic bacteria, pasteurisation will also destroy spoilage
bacteria and denature enzymes. This has the effect of extending the shelf-life of milk, both
chemically and microbiologically. Therefore pasteurisation is a critical control point in the
process.

A Phosphastase test must be carried out to show pasteurisation was effective.(<350mU/L =
Pass) All tests are recorded.
Raw milk contains acid and alkaline phosphatases. These enzymes catalyse the hydrolysis of
certain phosphate esters. The thermal stability of alkaline phosphatase (AP) in milk is slightly
higher than that of Microbacterium tuberculosis. AP is inactivated by heating milk to 72C and
holding for 15seconds. Inactivation of AP ensures the destruction of Microbacterium
tuberculosis. Adequately pasteurised milk will be phosphate negative.

Homogenisation
Homogenisation process allows two immiscible liquids to become mixed. This is achieved by
turning one of the liquids into a state consisting of extremely small particles distributed
uniformly throughout the other liquid.
When the milk is fed through the homogeniser, the workhead generates high shear rates. The
milk is forced through a small passage at high velocity. The disruption of the fat globules is
due to turbulence and cavitation.
While milk is forced through, the large fat globules are broken down into smaller ones.
Resulting in a size of 2-5 microns. This results in a stable emulsion, better mouth feel of the
product, reduced sensitivity to lipid oxidation.

Deaeration
Deaeration is the removal of oxygen and other dissolved gassed in the product. This is to
prevent/avoid undesirable changes in the final end product. Not only free air can be removed
but also mechanical air. Deaeration of a product can result in an oxygen level of <1ppm. This
improves product quality and shelf life.

Inoculation of culture starters
After deaeration of the milk, the temperature is maintained, The milk here is getting ready for
yogurt production. This heat treatment is to denature about 80% of the whey proteins,
particularly -lactoglobulin, which in turn reacts with the casein to form a more stable
micelle, and, to produce yoghurt with increased body and viscosity the starter cultures with are
used are, Lactobacillus bulgaricus and Streptococcus thermophiles.

Incubation/holding tanks
The milk is held for the fermentation process to be carried out. This occurs at a temperature
around 45C.
Cutting of yogurt pH
These bacteria form a symbiotic starter culture to ferment milk. By creating the starter culture
it increases the production of lactic acid in the fermentation process.

Streptococcus thermophilus starts to grow first dropping the milks pH from 6.6 to 5.0, and
produces carbon dioxide and lactic acid. These products stimulate Lactobacillus bulgaricus to
grow and further drop the pH to 4.2. The sugar found in milk is lactose, when the starter culture
is added to milk it breaks the lactose into glucose. After the sugar glucose is formed it. Then it
is fermented into lactic acid by the microorganisms.

The lactic acid decreases the pH of the milk and causes the casein, protein found in milk,
molecules to denature and stick together. The milk then curdles to produce yogurt
Filtration
Filtration of yogurt can remove the excess whey from fermentation process and gasses which
were produced form the starter cultures. This improves quality and shelf life of the product.
Filtration membrane used in this process is 0.5mm.

Yogurt Holding Tanks
After filtration the yogurt is cooled and then passed into yogurt holding tanks. The tanks here
keep the yogurt at the right temperature under atmospheric pressure. The yogurt is gently
agitated to keep the yogurt mixed with no whey separation and to keep a good consistency for
the product.
Metal Detection
Metal detection is a very important procedure in the manufacturing process. The yogurt is
frequently checked using a pipeline metal detector prior to final processing and final packaging.
The product is normally pumped through a non-metallic pipeline which passes through the
detector. Removal of contaminated product is achieved through the use of automated reject
valves which divert the product flow out of the process. Any high viscosity products that are
being produced which have the potential to solidify in the pipeline, there are heated pipelines
and valves are used, to limit pipe blockages. This will remove all contaminated substances
from the product, resulting in a high quality and safe product.
Blast Chilling
Blast chillers/freezers rapidly chill foods from a temperature of 140C to 40C in less than two
hours. As for yogurt, this will be even less. Blast chillers are ideal for chilling foods quickly
that are made on a daily basis. Blast chillers and freezers have powerful fans that create a fast
even air flow that is very cold. It uses a high-powered refrigeration system to blast the cold air
laterally over the product at high speed, extracting heat at an optimum rate, whilst maintaining
food quality. After the chill or freeze cycle is complete, the equipment switches into Hold mode
to keep the food at the required temperature.
Traying/Packaging
After the yogurt has been chilled, it is then ready to be put into yogurt pots. These are single
yogurt pots chosen for this product. The machine used here is the Automatic Rotary Type Cup
Filling & Sealing Machine SP-2502.
Cups fall into the holders on the machine, there are two stacks of yogurt cups, were two falls
each time into the individual holders. These are then passed along to the dust and blow suction
system. This takes away any access particles away from the cup. It passes on to a UV sterilizer,
this kills all microbes that may be present in the cups which could have got contaminated during
storage. It provides a sterile environment for the yoghurt. It moves on to the piston filler where
the cup fills up with the chilled yogurt from the blast chillier.
The amount of yogurt is poured out is calibrated on the machine.
The cups are ready to be sealed, they are flushed with nitrogen, and the oxygen is reduced so
that a longer shelf life can be obtained from the product. The yogurt cup is then sealed, brought
to the out feed system of the machine where a lever comes down and sucks the yogurt filled
cups out on to the vender belt to the labelling machine.
The yogurt cups pass though the labelling machine, where is puts on a sleeve around the yogurt
cup, stating all the requirements, such as yogurt name and nutritional information. A label is
also stuck on the lid of the yogurt stating the best before date.

Cold storage/Dispatch
The yogurts are taken of the labelling line and are stored at 4C in trays/ boxes in cold storage
rooms. These are now ready to be picked up by the truckers through dispatch. A physical test
is done before any of the yogurts are dispatched. The Yogurt is now sold to consumers.
1.6 Verification of flow diagram
1.6.1
The HACCP food safety team verifies the accuracy of the flow diagrams by on-site audit and
challenge at least annually. Daily and seasonal variations are considered and evaluated.
Records of verified flow diagrams are maintained.

1.7 List all potential hazards associated with each process step, conduct a
hazard analysis and consider any measures to control identified hazards
1.7.1
The HACCP food safety team identifies and records all the potential hazards that are
reasonably expected to occur at each step in relation to product, process and facilities.
This includes hazards present in raw materials, those introduced during the process or surviving
the process steps, and allergen risks. It also takes account of the preceding and following steps
in the process chain.
Fab Foods uses Risk Analysis to establish Hazards and uses it in conjunction with Food
Standards such as Food Safety Requirements, HACCP, Good Manufacturing & Hygiene
Practices and Total Quality Management to put an effective Food Management programme in
place.


Table 8: Risk Analysis in conjunction with Food Standards such as Food Safety
Requirements, HACCP, Good Manufacturing & Hygiene Practices and Total Quality
Management.





1.7.2
The HACCP food safety team conducts a hazard analysis to identify hazards which need to be
prevented, eliminated or reduced to acceptable levels. Consideration are given to the following:
likely occurrence of hazard
severity of the effects on consumer safety
vulnerability of those exposed
survival and multiplication of micro-organisms of specific concern to the product
presence or production of toxins, chemicals or foreign bodies
contamination of raw materials, intermediate/semi-processed or finished product.
Where elimination of the hazard is not practical, justification for acceptable levels of the hazard
in the finished product shall be determined and documented.
1.7.3
The HACCP food safety team considers the control measures necessary to prevent or eliminate
a food safety hazard or reduce it to an acceptable level. Where the control is achieved through
existing prerequisite programmes, this is stated and the adequacy of the programme to control
the hazard is validated.

Step

Process step

Hazards
Control
measures
Critical
limits
Monitoring
procedure
Corrective
action


1(a)

Raw Milk
(Receive Milk)

Presence of
micro-
organisms
Microbiologi
cal analysis.
Keep records
for each
tanker route

Bactoscan
results

Raw milk
procedure
Reject milk if
not to
microbiologic
al limits




1(b)



Raw milk
(Release tests)


Antibiotics

Foreign
material
Rosa test
Kundrat test
ATK test
In-line filter.
Inspect
tanker before
offloading.
Quality of
gaskets


Negative

No damage
gaskets


Raw milk
procedure

Raw milk
procedure


Reject milk
Follow up

Daily tanker
inspections

1(c)
Raw milk
(Cooling)

Microbial

Temperature
Milk
Cooled to <
3
o
C
Cold chain
procedure
Maintenance
of ice banks


1(d)


Raw milk (Silo
relase)

Microbial

Chemical
risk

Temperature
and time

Cleaning
Milk to be
kept at
minimum
of 3
o
C
Within
parameters

Cold chain
procedure

GMP
Maintenance
of silos

Quarterly
check by
supplier of
chemicals


2(a)

Cream
separation

Chemical
risk


Cleaning

Within
parameters

GMP
SOCP
Quarterly
check by
supplier of
chemicals


3(a)

Homogenisatio
n

Chemical
risk


Cleaning

Within
parameters

GMP
SOCP
Quarterly
check by
supplier of
chemicals
4(a) Pasteurisation Microbial Temperature
and time
Temperatur
e and time
GMP WI
GLP
Re-pasteurise

4(b)
Pasteurisation
(Transfer of
milk to holding
tank)

Microbial

Cleaning
Wash not
more than
24 h before

Visual on
PC display

Wash

5
Loading milk
for mixing

Microbial

Cleaning
Wash not
more than
24 h before
Visual on
PC display

Wash

6

Powder mixing
Physical
foreign
material
Production
and process
control
Wash not
more than
24 h before
Visual on
PC display

Wash

7
T105 to storage
tank

Microbial

Cleaning
Wash not
more than
24 h before
Visual on
PC display

Wash


8

Pasteurisation
and
homogenisation
process


Microbial


Time and
temperature

Pasteurisati
on
Temperature
& time
Temperatur
e and
recorder
and visual
on PC
display
Empty
pasteuriser
and repeat
washing and
sanitisation



9

Cooling down
to maturation
temperature and
ferment
addition



Microbial



Temperature



Temperature
Temperatur
e and
recorder
and visual
on PC
display
Too high: can
be cooled
with ice
water; too
low; stop the
process

10
Maturation and
breaking of
curd

Microbial

Cleaning
Wash not
more than
24 h before
Visual on
PC display

Wash


11
Cooling down,
smoothing with
filter and
transfer to
storage tank


Microbial


Cleaning

Wash 1
hour before

Visual on
PC display


Wash

12
Addition of
sterile apple
fruit pieces

Microbial

Cleaning
Wash 24 h
before
Visual on
PC display

Wash
13 Packing Microbial Cleaning Wash 24 h
before
Visual on
PC display
Wash

14

Storage

Microbial

Lab test

< 4C 24 h
Viscosity
Coliform
Count
Visual on PC
display

15

Dispatch

Microbial

Temperature

< 4C
Pre-cool
temperatur
e
Visual on PC
display


1.8 Determination of the critical control points (CCP)
1.8.1 For each hazard that requires control, control points are reviewed to identify those that
are critical. CCPs are those control points which are required in order to prevent or eliminate a
food safety hazard or reduce it to an acceptable level. If a hazard is identified at a step where
control is necessary for safety but the control does not exist, the product or process shall be
modified at that step, or at an earlier or later step, to provide a control measure.
Fab Foods implements a system by which critical points can be identified.
Table 9: Decision Tree used by company to establish Critical Control Points.









Simplified Decision Tree
YES NO
NO YES
CCP Not CCP Not CCP
Ref: Advi sed by the Chartered Insti tute of Envi ronmental Heal th (C.I.E.H) U.K.
Q2. Is there a later step at which this
hazard is or can be controlled? (Under
your control)
Would a loss of control at this point result in a realistic risk of illness or
injury?
Results of Decision Tree for CCP Determination
Step Process step Hazards Control measures Control point
1(a) Raw Milk
(Receive Milk)
Presence of micro-
organisms
Microbiological analysis.
Keep records for each tanker
route
CP
1(b) Raw milk
(Release tests)
Antibiotics

Foreign material
Rosa test Kundrat test ATK test
In-line filter. Inspect tanker
before offloading. Quality of
gaskets
CCP

CCP
1(c) Raw milk
(Cooling)
Microbial Temperature CP
1(d) Raw milk (Silo
relase)
Microbial

Chemical risk
Temperature and time

Cleaning
CP


GMP
2(a) Cream
separation
Chemical risk Cleaning GMP
3(a) Homogenisatio
n
Chemical risk Cleaning GMP
4(a) Pasteurisation Microbial Temperature and time CCP
4(b) Pasteurisation
(Transfer of
milk to holding
tank)
Microbial Cleaning GMP
5 Loading milk
for mixing
Microbial Cleaning GMP
6 Powder mixing Physical foreign
material
Production and process control GMP
7 T105 to storage
tank
Microbial Cleaning GMP
8 Pasteurisation
and
homogenisation
process
Microbial Time and temperature CCP
9 Cooling down
to maturation
temperature and
ferment
addition
Microbial Temperature CCP
10 Maturation and
breaking of
curd
Microbial Cleaning GMP
11 Cooling down,
smoothing with
filter and
transfer to
storage tank
Microbial Cleaning GMP
12 Addition of
sterile apple
fruit pieces
Microbial Cleaning GMP
13 Packing Microbial Cleaning GMP
14 Storage Microbial Lab test CP
15 Dispatch Microbial Temperature CP

Fab Foods recognises the below as Critical Control Points in the production of the
product.
1. The presence of antibiotics, and foreign material in raw milk,
2. Effective pasteurisation and homogenisation,
3. Maintaining the correct fermentation Temperatures

1.9 Establishment critical limits for each CCP
1.9.1
For each CCP, the appropriate critical limits are defined in order to identify clearly whether the
process is in or out of control. Critical limits include:
measurable wherever possible, e.g. time, temperature, pH
supported by clear guidance or examples where measures are subjective, e.g.
photographs.
1.9.2
The HACCP food safety team validate each CCP. Documented evidence show that the control
measures selected and critical limits identified are capable of consistently controlling the
hazard to the specified acceptable level.
1.10 Establishment of a monitoring system for each CCP
1.10.1
A monitoring procedure is established for each CCP to ensure compliance with critical limits.
The monitoring system is able to detect loss of control of CCPs and wherever possible provides
information in time for corrective action to be taken. Means of monitoring include:
online measurement
offline measurement
continuous measurement, e.g. thermographs, pH meters etc.
where discontinuous measurement is used, the system ensures that the sample taken is
representative of the batch of product.

1.10.2
Records associated with the monitoring of each CCP include the date, time and result of
measurement and are signed by the person responsible for the monitoring and verified, as
appropriate, by an authorised person. Where records are in electronic form there is evidence
that records have been checked and verified.

1.11 Establishment a corrective action plan
1.11.1
The HACCP food safety team specifies and documents the corrective action to be taken when
monitored results indicate a failure to meet a control limit, or when monitored results indicate
a trend towards loss of control. This includes the action to be taken by nominated personnel
with regard to any products that have been manufactured during the period when the process
was out of control.

1.12 Establishment of verification procedures
1.12.1
Procedures of verification are established to confirm that the HACCP plan, including controls
managed by prerequisite programmes, are effective. Examples of verification activities
include:
internal audits
review of records where acceptable limits have been exceeded
review of complaints by enforcement authorities or customers
review of incidents of product withdrawal or recall.
Results of verification are recorded and communicated to the HACCP food safety team.



Critical Control Points Management

Critical
Control
Point
(CCP)


Significan
t
Hazard
Critical
Limits for
each
preventat
ive
measure

Monitoring




Correcti
ve
actions



Records


Verificati
on
What How Frequenc
y
Who



Presence of
Antibiotics
in raw milk
Allergic
reactions
to
residues,
Developm
ent of
resistant
strains of
bacteria,
Removes
starter
cultures




See Table
11 Below


Presence
of
antibiotic
s
Mainly
Beta-
Lactam



DSM
Delvo-
Test
&
Charm
Test
On each
batch of
milk in all
tankers,
silos,
cream
vats,
fermentati
on tanks.




On site
micro lab.
Reject &
Dispose,
inform
Farm
Liaison
Officer
and the
Dep.t of
Agricult
ure


Corrective
action log.
Antibiotic
testing log.
Milk &
Yogurts
quality
log.


For each
batch
processed
the QA
superviso
r will
review
each log





Presence of
foreign
material in
raw milk


Can cause
physical,
biological
and/or
chemical
adverse
effects.




Foreign
material
must be
absent in
milk.





Presence
of
Foreign
Matter


ISO
5538:200
4
Milk -
Inspectio
n by
attributes

On each
batch of
milk in all
tankers,
silos,
cream
vats,
fermentati
on tanks.





On site
micro lab.
Remove
or Reject
&
Dispose,
inform
Farm
Liaison
Officer
and the
Dep.t of
Agricult
ure



Corrective
action log.
Antibiotic
testing log.
Milk &
Yogurts
quality
log.


For each
batch
processed
the QA
superviso
r will
review
each log





HTST

Pasteurisat
ion


If not
carried out
correctly,
harmful
spoilage
m/org can
grow
72C for
20
seconds


TVC
<1,000
cfu/ml on
day 1;
<5,000
cfu/ml on
day 12


Temperat
ure
0
C

Presence
of cfus
per ml of
the
sample




Check &
sign-off
on
continuou
s chart
recorder





Every 2
hours




Pasteurize
r Operator


Empty
pasteuris
er and
repeat
washing
and
sanitisati
on


Corrective
action log.
Pasteurisat
ion testing
log. Milk
& Yogurts
quality
log.


For each
batch
processed
the QA
superviso
r will
review
each log




Maintainin
g the
correct
Fermentati
on Temp.





Microbial





25 30
o
C





Temperat
ure
0
C




Temperat
ure and
recorder
and visual
on PC
display





Every 30
minutes




Fermentat
ion
Superviso
r

Too
high: can
be
cooled
with ice
water;
too low;
stop the
process


Corrective
action log.
Fermentati
on testing
log.
Yogurt
quality
log.


For each
batch
processed
the QA
superviso
r will
review
each log


Table 10: Critical Control Points Management including; Significant Hazard, Critical
Limits, Monitoring, Corrective actions, Records, and Verification








Table 11: Comparison of the EU maximum residue limits (EEC Regulation 2377/90 and
amendments) with the sensitivities of the microbial inhibition assays for the detection of
antibiotics in milk.












1.13 HACCP Plan Overview
Step Process step Hazards Control
measures
Control
point
Critical
limits
Monitoring
procedure
s
Corrective
action


1(a)

Raw Milk
(Receive Milk)

Presence of
micro-
organisms
Microbiologi
cal analysis.
Keep records
for each
tanker route


CP

Bactoscan
results

Raw milk
procedure
Reject milk if
not to
microbiologic
al limits




1(b)



Raw milk
(Release tests)


Antibiotics

Foreign
material
Rosa test
Kundrat test
ATK test
In-line filter.
Inspect
tanker before
offloading.
Quality of
gaskets



CCP

CCP



Negative

No damage
gaskets


Raw milk
procedure

Raw milk
procedure


Reject milk
Follow up

Daily tanker
inspections

1(c)
Raw milk
(Cooling)

Microbial

Temperature

CP
Milk
Cooled to <
3
o
C
Cold chain
procedure
Maintenance
of ice banks



1(d)



Raw milk (Silo
relase)


Microbial

Chemical
risk


Temperature
and time

Cleaning


CP


GMP

Milk to be
kept at
minimum
of 3
o
C
Within
parameters


Cold chain
procedure

GMP
Maintenance
of silos

Quarterly
check by
supplier of
chemicals


2(a)

Cream
separation

Chemical
risk


Cleaning


GMP

Within
parameters

GMP
SOCP
Quarterly
check by
supplier of
chemicals


3(a)

Homogenisatio
n

Chemical
risk

Cleaning

GMP

Within
parameters

GMP
SOCP
Quarterly
check by
supplier of
chemicals
4(a) Pasteurisation Microbial Temperature
and time
CCP Temperatur
e and time
GMP WI
GLP
Re-pasteurise

4(b)
Pasteurisation
(Transfer of
milk to holding
tank)

Microbial

Cleaning

GMP
Wash not
more than
24 h before

Visual on
PC display

Wash

5
Loading milk
for mixing

Microbial

Cleaning

GMP
Wash not
more than
24 h before
Visual on
PC display

Wash

6

Powder mixing
Physical
foreign
material
Production
and process
control

GMP
Wash not
more than
24 h before
Visual on
PC display

Wash

7
T105 to storage
tank

Microbial

Cleaning

GMP
Wash not
more than
24 h before
Visual on
PC display

Wash


8

Pasteurisation
and
homogenisation
process


Microbial


Time and
temperature


CCP

Pasteurisati
on
Temperature
& time
Temperatur
e &
recorder &
visual on
PC display
Empty
pasteuriser
and repeat
washing and
sanitisation



9

Cooling down
to maturation
temperature and
ferment
addition



Microbial



Temperature



CCP



Temperature
Temperatur
e and
recorder
and visual
on PC
display
Too high: can
be cooled
with ice
water; too
low; stop the
process

10
Maturation and
breaking of
curd

Microbial

Cleaning

GMP
Wash not
more than
24 h before
Visual on
PC display

Wash


11
Cooling down,
smoothing with
filter and
transfer to
storage tank


Microbial


Cleaning


GMP


Wash 1
hour before


Visual on
PC display


Wash

12
Addition of
sterile apple
fruit pieces

Microbial

Cleaning

GMP
Wash 24 h
before
Visual on
PC display

Wash
13 Packing Microbial Cleaning GMP Wash 24 h
before
Visual on
PC display
Wash

14

Storage

Microbial

Lab test

CP

< 4C 24 h
Viscosity
Coliform
Count
Visual on PC
display

15

Dispatch

Microbial

Temperature

CP

< 4C
Pre-cool
temperatur
e
Visual on PC
display

Table 12: HACCP Plan Overview (where CP = Control Point, CCP = Critical Control
Point, GMP = Good Manufacturing Practice, SOCP = Standard Operating Cleaning
Procedure)











1.14 HACCP documentation and record keeping
1.14.1
Documentation and record keeping are sufficient to enable the company to verify that the
HACCP controls, including controls managed by prerequisite programmes, are in place and
maintained.

Doc &
Record
Ingredients Product safety Processing Packaging Storage and
distribution
Deviations
and
corrective
actions
Supplier
certification -
documenting
compliance
with
processors
specifications
along with
Certificates of
Analysis

Data and
records to
establish the
efficacy of
barriers in
maintaining
product safety



Records
from all
monitored
CCPs


Records
indicating
compliance
with
specifications
of packaging
materials





Temperature
records




Indicating
approved
revisions and
changes in
ingredients,
formulations,
processing,
packaging
and
distribution
control


Processor
audit records
verifying
supplier
compliance
Data and
records
establishing the
safe shelf life
of the product,
as age of
product can
affect safety

Records
verifying
the
continued
adequacy
of the
process


Records
indicating
compliance
with sealing
specifications




Records
showing that
no product is
shipped after
shelf life date







Storage
temperature
records for all
ingredients
Documentation
of the
adequacy
of the
processing
procedures
from a
knowledgeable
process
authority

Storage
temperature
records for
temperature
sensitive
ingredients


Table 13: Documentation and Record keeping of the HACCP standard.


Documents used to control HACCP:












Sample documents and records from I.S. 340:2007



1.15 Review of the HACCP plan
1.15.1
The HACCP food safety team reviews the HACCP plan and prerequisite programmes annually
and prior to any changes which may affect product safety. Changes can include
change in raw materials or supplier of raw materials
change in ingredients/recipe
change in processing conditions or equipment
change in packaging, storage or distribution conditions
change in consumer use
emergence of a new risk, for example adulteration of an ingredient
developments in scientific information associated with ingredients, process or product.
Appropriate changes resulting from the review shall be incorporated into the HACCP plan
and/or prerequisite programmes, fully documented and validation recorded.