Quality Plan

Sl. No. Product Parameter of inspection Stage at which inspection is carried out Criteria for Approval Inspection mode
By taking a sample of 120 ml, after agitating as per the procedure in QAM

Doc. No.Q/Doc/07
Rev. No.R1(30.01.03)

Page 1 of 9
Frequency of inspection

Responsi-bility

Raw Chilled Milk in tankers from Chilling Centers & other Dairies Raw Chilled Milk from Chilling Centers & other Dairies Raw Chilled Milk

Temp.C, COB, Acidity%, CLR, Fat %, SNF % & MBRT min.,

Before a tanker is unloaded at reception bay

As defined Quality Assurance Manual (QAM) (Q/QC/Doc/01) As defined Quality Assurance Manual (QAM) (Q/QC/Doc/01) As defined Quality Assurance Manual (QAM) (Q/QC/Doc/01)

Each compartment of tanker to be received in Mega Dairy shall be tested From any Raw Milk Silo or One randomly selected tanker in a day
Beginning of every Shift and whenever the Processing Incharge requests; Each compartment of tanker to be dispatched

Shift In Charge in Quality Control Section

Adulterants and Neutralizers

Silos & Storage Tanks; Before a tanker is unloaded at reception bay Silos and other Storage Tanks; When tankers are loaded for dispatching to other Dairies

Temp.C, COB, Acidity%, CLR, Fat %, SNF % & MBRT min.

By taking a sample of 120 ml from any Silo or from tanker by agitating as per the procedure in QAM By taking a sample of 120 ml from any Silo or from tanker by agitating as per the procedure in QAM

Shift In Charge in Quality Control Section Shift In Charge in Quality Control Section

Prepared by
B.Nataraj, Asst. Manager (QC)

Checked by
S.A.Prakash, Asst. Manager (QC)

Approved by
K.V.Jagannatha Rao, Manager (Production)

Quality Plan
Sl. No. Product Parameter of inspection Stage at which inspection is carried out Criteria for Approval Inspection mode
By taking a sample of 120 ml from any Silo or from tanker by agitating as per the procedure in QAM By taking a sample of 120 ml from any Silo; Any randomly selected milk sachet By taking a sample of 120 ml from any Silo or from tanker by agitating as per the procedure in QAM

Doc. No.Q/Doc/07
Rev. No.R1(30.01.03)

Page 2 of 9

Frequency of inspection Beginning of every Shift and whenever the Processing Incharge requests; Each compartment of tanker to be dispatched

Responsi-bility

Pasteurized Whole Milk

Temp.C, COB, Acidity%, CLR, Fat %, SNF % & MBRT min. and Phosphatase Test

Silos and other Storage Tanks; After a tanker is loaded

As defined Quality Assurance Manual (QAM) (Q/QC/Doc/01) Shall be within the Internationally specified limits As defined Quality Assurance Manual (QAM) (Q/QC/Doc/01)

Shift In Charge in Quality Control Section

Pasteurized Whole Milk/ Processed Milk in Sachets Pasteurized Toned Milk

Lead, Aflatoxin, Pesticides, Somatic Cell Count and Antibiotics

Silos and other Storage Tanks; Packed Milk in Cold Store Silos and other Storage Tanks; Before milk is issued for packing; Before milk is dispatched

Once in every three months by an External Agency Beginning of every Shift and whenever the Processing Incharge requests

Asst. Manager (QC)

Temp.C, COB, Acidity%, CLR, Fat %, SNF % & MBRT min. and Phosphatase Test,

Shift In Charge in Quality Control Section

Prepared by
B.Nataraj, Asst. Manager (QC)

Checked by
S.A.Prakash, Asst. Manager (QC)

Approved by
K.V.Jagannatha Rao, Manager (Production)

Quality Plan
Sl. No. Stage at which inspection is carried out Criteria for Approval Inspection mode
By taking a sample of 120 ml from any Silo or from tanker by agitating as per the procedure in QAM By aseptically taking a sample of 20 ml from any Silo or any other Storage tank or sachet to be tested By aseptically taking a sample of 20 ml from any Silo or any other Storage tank or sachet to be tested

Doc. No.Q/Doc/07
Rev. No.R1(30.01.03)

Page 3 of 9

Product

Parameter of inspection

Frequency of inspection

Responsi-bility

Pasteurized Full Cream Milk

Temp.C, COB, Acidity%, CLR, Fat %, SNF % & MBRT min. and Phosphatase Test,

Silos and other Storage Tanks; Before milk is issued for packing; Before milk is dispatched Pasteurized Milk Silos or Packed Milk Sachets

As defined Quality Assurance Manual (QAM) (Q/QC/Doc/01) As defined Quality Assurance Manual (QAM) (Q/QC/Doc/01)

Beginning of every Shift and whenever the Processing Incharge requests Daily

Shift In Charge in Quality Control Section

Pasteurized Toned Milk

Standard Plate Count and Coliform Count

Chemist/QCO

Pasteurized Full Cream Milk

Standard Plate Count and Coliform Count

Pasteurized Milk As defined in Silos or Packed Quality Milk Sachets Assurance Manual (QAM) (Q/QC/Doc/01)

Daily

Chemist/QCO

Prepared by
B.Nataraj, Asst. Manager (QC)

Checked by
S.A.Prakash, Asst. Manager (QC)

Approved by
K.V.Jagannatha Rao, Manager (Production)

Quality Plan
Sl. No. Product Parameter of inspection Stage at which inspection is carried out Criteria for Approval Inspection mode
By taking a sample of 120 ml from any Silo or from tanker by agitating as per the procedure in QAM By taking a sample of 120 ml from any Cream Tank

Doc. No.Q/Doc/07
Rev. No.R1(30.01.03)

Page 4 of 9
Frequency of inspection Beginning of every Shift and whenever the Processing Incharge requests; Each Tanker to be dispatched After completion of separation and whenever the Processing Incharge requests

Responsi-bility

10

Pasteurized Skim Milk

Temp.C, COB, Acidity%, CLR, Fat %, SNF % & MBRT min. and Phosphatase Test,

Silos and other Storage Tanks; After a tanker is loaded

As defined Quality Assurance Manual (QAM) (Q/QC/Doc/01) -

Shift In Charge in Quality Control Section

11

Cream

Fat % and Acidity %

Cream Storage Tanks

Shift In Charge in Quality Control Section Shift In Charge in Quality Control Section

12

Milk for Curds Making

Temp.C, COB, Acidity%, CLR, Fat %, SNF %

Curd Milk Tank

As defined Quality Assurance Manual (QAM) (Q/QC/Doc/01)

By taking a sample of 120 ml from any Curd Milk Tank

Every Batch

Prepared by
B.Nataraj, Asst. Manager (QC)

Checked by
S.A.Prakash, Asst. Manager (QC)

Approved by
K.V.Jagannatha Rao, Manager (Production)

Quality Plan
Sl. No. Product Parameter of inspection Stage at which inspection is carried out Criteria for Approval Inspection mode
By taking a sample of 100 gm from any randomly selected can or sample of one randomly selected 200 or 500 gm sachet from each batch

Doc. No.Q/Doc/07
Rev. No.R1(30.01.03)

Page 5 of 9

Frequency of inspection

Responsi-bility

13

Curds in Cans and Sachets

Flavor, Body and Texture and Acidity

At the Incubation Room and in Cold Store

As defined Quality Assurance Manual (QAM) (Q/QC/Doc/01) Cans shall be properly cleaned

Beginning of every Shift and every batch

Shift In Charge in Quality Control Section

14

Cleaned Cans in Prepac and Curds Section Rinse test for Cleaned Cans in Prepac and Curds Section

Cleanliness by Visual inspection and Proper rinsing of detergent by Phenolphthalein test Microbial Count Rinse Test

After cleaning

Select Cans at random and inspect

Everyday

Shift In Charge in Quality Control Section Chemist/QCO

15

After cleaning

As defined Quality Assurance Manual (QAM) (Q/QC/Doc/01)

Select Cans at random

Once in a Week

Prepared by
B.Nataraj, Asst. Manager (QC)

Checked by
S.A.Prakash, Asst. Manager (QC)

Approved by
K.V.Jagannatha Rao, Manager (Production)

Quality Plan
Sl. No. Product Parameter of inspection Stage at which inspection is carried out Criteria for Approval Inspection mode Frequency of inspection

Doc. No.Q/Doc/07
Rev. No.R1(30.01.03)

Page 6 of 9

Responsi-bility

16

17

Cleanliness of Silos, Storage Tanks, Tankers and other Equipments Skim Milk Powder

Microbial Count Swab Test

After Cleaning

As defined Quality Assurance Manual (QAM) (Q/QC/Doc/01) As defined Quality Assurance Manual (QAM) (Q/QC/Doc/01) As defined Quality Assurance Manual (QAM) (Q/QC/Doc/01)

Select Silos/ Storage Tanks/ Tankers at random

Select bags at random from each batch and inspect; Number of bags to be inspected in a batch is decided as per the sampling plans given in QAM Select a bag at random from each batch and inspect

Once in every Week

Chemist/QCO

Flavor, Moisture, Fat, Acidity and Solubility Index, Scorched Particles

After the Production & Before Using for reconstitution After the Production

Everyday

Chemist/QCO

18

Skim Milk Powder

Standard Plate Count and Coliform

Once in a Week

Chemist/QCO

Prepared by
B.Nataraj, Asst. Manager (QC)

Checked by
S.A.Prakash, Asst. Manager (QC)

Approved by
K.V.Jagannatha Rao, Manager (Production)

Quality Plan
Sl. No. Product Parameter of inspection Stage at which inspection is carried out Criteria for Approval Inspection mode Frequency of inspection

Doc. No.Q/Doc/07
Rev. No.R1(30.01.03)

Page 7 of 9

Responsi-bility

19

Road Milk Tankers

Cleanliness of Road Milk Tankers

After Cleaing

Tankers shall be properly cleaned

Select Cleaned Tankers at random

Every day

Chemist/QCO

20

Hygiene in the Various Sections of the Plant Crates

As per checklist for each Area

At random at any time

Shall conform to the Checklist

Visual Observation of the Ares

Everyday

Chemist/QCO

21

Cleanliness of Crates

After cleaning

Crates shall be clean

Select Cleaned Crates at random

Every day

Chemist/QCO

Prepared by
B.Nataraj, Asst. Manager (QC)

Checked by
S.A.Prakash, Asst. Manager (QC)

Approved by
K.V.Jagannatha Rao, Manager (Production)

Quality Plan
Sl. No. Product Parameter of inspection Stage at which inspection is carried out Criteria for Approval Inspection mode
By taking 200 ml of sample of Water from the Water Storage Tanks

Doc. No.Q/Doc/07
Rev. No.R1(30.01.03)

Page 8 of 9
Frequency of inspection

Responsi-bility

22

Water

Hardness and Chlorine Content

From Water Tanks

As defined Quality Assurance Manual (QAM) (Q/QC/Doc/01) As defined Quality Assurance Manual (QAM) (Q/QC/Doc/01) Strength shall not be less than O.8% Strength shall not be less than O.8%

Every day

Chemist/QCO

23

Water

Colifroms

From Water Tanks

By aseptically taking 50 ml of sample of Water from the Water Storage Tanks

Once in a Week

Chemist/QCO

24

CIP Lye Solution CIP Acid Solution

Strength of the CIP Lye Solution Strength of the CIP AcidSolution

From CIP Lye Tanks From CIP Lye Tanks

By taking 100 ml of sample of solution from the CIP Tanks By taking 100 ml of sample of solution from the CIP Tanks

Every day

Shift In Charge in Quality Control Section Shift In Charge in Quality Control Section

25

Every day

Prepared by
B.Nataraj, Asst. Manager (QC)

Checked by
S.A.Prakash, Asst. Manager (QC)

Approved by
K.V.Jagannatha Rao, Manager (Production)

Quality Plan
Sl. No. Product Parameter of inspection Stage at which inspection is carried out Criteria for Approval Inspection mode
Select rolls at random from each supplied lot and inspect; Number of rolls to be inspected in a batch is decided as per the sampling plans given in QAM Select units at random from each supplied lot and inspect; Number of units to be inspected in a batch is decided as per the sampling plans given in QAM

Doc. No.Q/Doc/07
Rev. No.R1(30.01.03)

Page 9 of 9

Frequency of inspection

Responsi-bility

26

LDPE Film for Milk and Curds

As defined Quality Assurance Manual (Q/QC/Doc/01)

After every supply

As defined Quality Assurance Manual (QAM) (Q/QC/Doc/01) As defined Quality Assurance Manual (QAM) (Q/QC/Doc/01)

Every lot supplied

Film Testing Committe

27

Caustic Soda Flakes, Lye, Soda Ash, Liquid Detergent, Nitric Acid other Consumables

As defined Quality Assurance Manual (Q/QC/Doc/01)

After every supply

Every lot supplied

Chemist/QCO

Prepared by
B.Nataraj, Asst. Manager (QC)

Checked by
S.A.Prakash, Asst. Manager (QC)

Approved by
K.V.Jagannatha Rao, Manager (Production)