Hazard analysis for set yoghurt CCP/OPRP

CCP/
OPRP
No

Raw
material/
food contact
material/
Process
control

OPRP1

Milk Reception

Potential
hazard

Presence

Critical limit
What

of

vegetative
pathogenic

micro

TPC (cfu/mL)

Raw milk

Daily basis

Milk

3 x 105 (farm)

microbiolo

- TPC and

receiving

100 x 105 (external)

gical

organisms due to
bad handling

Monitoring
How
When

Parameters

Who

QC

Hazard analysis
Correction
Report/
Verification
and
Responsibility
Corrective
action
Correction if

Report Milk

Continuous

limit exceeds

Reception

checking of

Coliform

withhold

microbiology log

raw milk

test

unloading

Doc No: 02/REC/MILK/04

samples

Coliform (cfu/mL)
< 100

Corrective
action

Responsibility
QC/FT

Rejection
CCP1

Milk Reception

Presence
antibiotics

of

Negative
antibiotic kit

on

antibiotics

Antibiotic

Milk

test kit

receiving

QC

Correction
Withhold
unloading

Report Milk

Re sampling

Reception log

and re testing

Doc No: 02/REC/MLK/01

Corrective
action -

Responsibility

Rejection

QC/FT

CCP2

Milk

storage

and release

Multiplication

of

vegetative
pathogenic

MO

KQ = 6

Raw milk

KQ test

Milk

Acidity=0.145-.160

quality

TA

receiving

APT = 74 negative

parameters

Alcohol

due to time/temp

QC

Correction

milk

releasing

log/process

Corrective

and release

Retention

of

cleaning agents in

Raw
storage

Re

sampling

and re testing

control
Doc No : 02/REC/MILK/03

action
Milk storage

Withhold

test

abuse

CCP3

Report

Responsibility

Rejection

QC/FT

Correction -

Report

Rinse water free

Rinse

Titration

Before

from soda/ acid

water

method

milk

Withhold

record sheet

unloading

releasing

Doc No: 01/GMP/YO/04

tanks/silos

QC

CIP

Re

sampling

and re testing

Corrective
action

Re

CIP
CCP4

Pasteurization

Survival of
vegetative
pathogenic M/O

Temperature
o

should be 72 C or
o

90 C

abuse

Control

Pasteurizi

QC /

Correction

Report Process

Maintenance

re

panel plant

ng

operator

Stop the

control log/

records on

processing

Production log

Pasteurizer

Doc No: 03/PRC/YO/01

time

mins/ 5 mins
OPRP2

Pre heating

Contamination
with pathogenic

TPC (cfu/mL)
3

1 x 10

MO passing
through PHE

QC

holding
Holding time 16

Coliform - negative

Tempertatu
and

due to time/temp

Responsibility

QC

Corrective

Responsibility

action Re

QC/ Plant

pasteurization

operator

Correction -If

Report - Doc No:

Continuous

01/GMP/YO/11

checking of

Rinse

Microbiolo

After CIP

water

gical

once a

exceeds, re

sample

analysis

month

-CIP

analysis

once per

periodical

Corrective

Responsibility-

month

ly

action

QC/Plant

increase the

operator/

frequency

samples

Maintenance

OPRP3

Filling at 44 0C
and sealing

Contamination
with pathogenic

TPC (cfu/mL)
3

1 x 10

MO passing
through filling

Coliform - negative

machines and

Raw

Microbiolo

At

material

gical

microbiolo

analysis

gical

QC

Correction if

Report - Doc No:

Continuous

receiving

exceeds

01/GMP/YO/12

checking of

for each

withhold

lot

releasing

samples
Responsibility

analysis

QC/FT

yoghurt cup /foil

Corrective
action

Rejection
CCP5

Incubation at

Multiplication of

Temperature 43

Tempertatu

Wall

Trolley

Correction

Report Yoghurt

Maintenance

44 0C

vegetative

45 oC

re

thermomet

transferri

Stop the

process control

records on

and

er and

ng from

production and

log

Incubation

Incubation

clock

incubator

sort out the

Doc No : 03/PRC/YO/04-

rooms

product

A,B,C

pathogenic MO
due to time and
temp abuse

Time 3 hrs to 4
hrs

QC

time

Doc No: 01/GMP/YO/16

Corrective

Responsibility

action

QC, Maintenance

adjusting the

officer

temperature
CCP6

Blast cooling at
0

4 C

Multiplication of

Temperature

Tempertatu

Wall

Trolley

4 5 C

re

thermomet

and
Time 12 hrs to 15

Blast

vegetative
pathogenic MO
due to time and
temp abuse

hrs

cooling

QC

Correction

Report Yoghurt

Maintenance

transferri

Stop the

process control

records on

er and

ng from

production and

log

Blast cooling

clock

blast

sort out the

Doc No: 03/PRC/YO/03-

rooms

cooler

product

A,B,C

time

Doc No: 01/GMP/YO/17

Corrective
action

Responsibility
QC, Maintenance

adjusting the

officer

temperature