PRODUCT DESCRIPTION & INTENDED USE OF GHEE

S. No. Particulars Description

1. Name Param Deshi Ghee
2. Composition Fat-99.7 %, Moisture-0.3 %
3. Physical & Chemical Liquid in Higher Temp above 40 deg.c., Granular in
Structure temp. range 25-30 deg.c, Semi solid at lower temp.
Heating of butter above 105C during
4. Preservation Method processing to convert it into ghee.
Keep in cool & dry place to prevent oxidation.

5. Inner Packaging Cake Pack, Tin Pack, Pouch Packing & Poly Jars

6. Outer Packaging All the packages are packed in Cartons.

7. Packaging Size 15 kg, 5litrs, 2 litrs,1litrs, ½ liters, 200ml.

8. Storage Condition Keep in cool & dry place

9. Method of Distribution Distributed at ambient temperature.

10. Shelf Life 12 Months

Batch No, Date of Manufacturing, Price, Weight, Veg
11. Specific Labeling Logo, Bar Code, Agmark Seal, MMPO No,
Instruction of storage

12. Consumer Preparations 1. Ready to eat.

2. For food preparations like sweets, veg & non
veg dishes.
Due to high fat & cholesterol not too much
13. Sensitive Population permissible for the persons suffering from coronary
diseases.

PROCESS FLOW DIAGRAM OF GHEE

Sampling
 Weighing

Receiving, RMRD
(Tankers & Village
Level Collection)

Sampling (Fat, SNF & Other Parameters) &

Organoleptic testing for taste, odor & color

Filtration CCP
(80microns)

Dump Tank

Chilling at or below 6ºC

For Curd Raw Milk Silo For Paneer

Preheating at Temp. 43±2ºC

 Cream Separator

Cream Skim Milk for SMP

Cream Pasteurization at Temp. CCP

79±3ºC for 15 seconds.

B
Raw Milk Silo

Cream Balance Tank

Churner for Butter Making

Butter Milk

Butter

Butter in Trolley

Butter Melting Vat (75 to 80ºC)

 Pre-stratification Tank 1&2

Ghee Cooking Kettle (108+1ºC) CCP

Ghee Settling Tank

Clarification

Ghee Storage Tank

Inspection & Testing

Cooling at 40 to 45ºC

Poly Filling Filling in Tins Cake Filling

Secondary Packaging
in Cartons
 D

Ghee Granulation Room

Transfer to Finished Goods Store

Storage

Dispatch

HAZARD ANALYSIS OF GHEE

S.No. Process Step Identify Potential Likelihood- Justification What Is this step Critical
Hazards High(H) Preventive Control Point (CCP)
introduced, Medium(M) Significant- Measures can
controlled or Low(L) S be applied to
enhanced at this Severity- Non- prevent the
step Critical, significant- significant
Serious, N.S hazard?
Major, Minor
of Hazard
1. Sampling Biological :Microbes Likelihood: H Microbes are already Controlled in No
Severity: present in the raw future step of
Minor milk so likelihood is cream
N.S high but it is pasteurization &
controlled in the cooking.
further step of Proper
pasteurization so it is sterilization of
NS. plunger, dipper &
scale.
Chemical: Antibiotics Likelihood: L Antibiotics are Proper washing No
Severity: checked from outside of utensils &
Major lab in definite material.
frequencies & if found Milk is
N.S present then the purchased only
supplier is black listed from approved
so likelihood is very suppliers.
low.
Physical : Metal, Likelihood: H Likelihood of physical G.M.P in place. No
Stones, Husk etc Severity: hazards is high but it Controlled in the
Minor is NS as it is future step of
N.S controlled in the Filtration.
further step of
filtration.
2. Weighing No hazards is
involved at this stage
as the weighing is
performed in the
covered condition
3. Receiving Biological : Microbes Likelihood: H Microbes are already Controlled in No
Severity: present in the raw future step of
Major milk so likelihood is pasteurization &
N.S high but it is cooking.
controlled in the Proper cleaning,
further step of sterilization of
pasteurization so it is equipments.
NS. Clean potable
water tested for
IS 10500 is
used.

Chemical: Caustic & Likelihood: L As the SOP of CIP well in No

Acid Residues Severity: cleaning is strongly place.
Major implemented so Proper cleaning,
N.S likelihood is low so it sterilization of
is NS. equipments.
Clean potable
water tested for
IS 10500 is
used.
Training has
been provided to
the working staff.
Physical : Metal, Likelihood: H Severity is minor as Controlled in No
Stones, Husk etc Severity: filtration step is future step of
Minor specifically design to filtration.
N.S remove this hazard.
So at this step the
 severity is minor.
4. Sampling No hazards are
involved in this step
as this step is
specifically designed
to detect any non
conformity in the
product.
5. Filtration Biological : Microbes Likelihood: H Microbes are already Controlled in No
Severity: present in the raw future step of
Minor milk so likelihood is pasteurization &
N.S high but it is cooking.
controlled in the Proper cleaning,
further step of sterilization of
pasteurization so it is equipments.
NS. Personnel
Hygiene policy is
in place.
Physical : Metal, Likelihood: H It is Significant as Nylon Sieves of CCP
Stones, Husk etc Severity: physical hazards have 80 mesh is used
Major to be controlled in this to remove
S step only & it can't be extraneous
controlled in any particles.
further step. Metal Policy is in
place.
6. Dump Tank Biological : Microbes Likelihood: H Microbes are already Controlled in No
Severity: present in the raw future step of
Minor milk so likelihood is pasteurization &
N.S high but it is cooking.
controlled in the Proper cleaning,
further step of sterilization of
pasteurization so it is equipments.
NS. Personnel
Hygiene policy is
in place.
Chemical: Detergent Likelihood: L As the SOP of Proper washing No
Residues Severity: cleaning is strongly of utensils &
Major implemented so material.
N.S likelihood is low Clean potable
hence it is NS. water tested for
IS 10500 is
used.
7. Chiller Biological : Microbes Likelihood: H Microbes are already Chilling of milk No (OPRP)
Severity: present in the raw below 6ºC to
Minor milk so likelihood is prevent microbial
N.S high but it is growth.
controlled in the Controlled in
further step of future step of
pasteurization so it is pasteurization &
NS. cooking.
Proper cleaning,
sterilization of
equipments.
Personnel
Hygiene policy is
in place.
Chemical: Caustic & Likelihood: M As the SOP of CIP well in No
Acid Residues Severity: Maj cleaning is strongly place.
implemented so Proper cleaning,
N.S likelihood is low sterilization of
hence it is NS. equipments.
Clean potable
water tested for
IS 10500 is
used.
Training has
been provided to
the working staff.
8. Raw Milk Silo Biological : Microbes Likelihood: H Microbes are already Storage of raw No
 Severity: present in the raw milk below 8ºC
Minor milk so likelihood is to retard
N.S high but it is microbial growth.
controlled in the Controlled in
further step of future step of
pasteurization so it is pasteurization &
NS. cooking.
Proper cleaning,
sterilization of
equipments.
Personnel
Hygiene policy is
in place.
Chemical: Caustic & Likelihood: M As the SOP of CIP well in No
Acid Residues Severity: Maj cleaning is strongly place.
implemented so Proper cleaning,
N.S likelihood is low sterilization of
hence it is NS. equipments.
Clean potable
water tested for
IS 10500 is
used.
Training has
been provided to
the working staff.
9. Preheating Biological : Likelihood: H Microbes are already Maintaining the No
Microbes: Pathogens Severity: present in the raw temperature of
Minor milk so likelihood is Milk at 43±2ºC.
N.S high but it is Controlled in
controlled in the future step of
further step of cream
pasteurization so it is pasteurization &
NS. cooking.
Chemical: Caustic & Likelihood: L As the SOP of CIP well in No
Acid Residues Severity: Maj cleaning is strongly place.
implemented so Proper cleaning,
N.S likelihood is low sterilization of
hence it is NS. equipments.
Clean potable
water tested for
IS 10500 is
used.
Training has
been provided to
the working staff.
10. Cream Chemical: Caustic & Likelihood: L As the SOP of CIP well in No
Acid Residues Severity: Maj cleaning is strongly place.
Separator implemented so Proper cleaning,
N.S likelihood is low sterilization of
hence it is NS. equipments.
Clean potable
water tested for
IS 10500 is
used.
Training has
been provided to
the working staff.
11. Cream Biological : Likelihood: H Microbes are already Maintaining the CCP
Microbes: Pathogens Severity: present in the raw temperature of
Pasteurizer Critical milk so likelihood is Cream at
S high and severity is 79±3ºC for 15
also critical so this seconds & then
step is designed to immediately
control the biological chilled to below
hazards. It is 10ºC to keep
significant as hazards control the
can't be controlled in microbial load.
any of the further CIP well in
steps. place.
 Chemical: Caustic & Likelihood: L As the SOP of CIP well in No
Acid Residues Severity: Maj cleaning is strongly place.
implemented so Proper cleaning,
N.S likelihood is low sterilization of
hence it is NS. equipments.
Clean potable
water tested for
IS 10500 is
used.
Training has
been provided to
the working staff.
12. Cream Chemical: Caustic & Likelihood: L As the SOP of CIP well in No
Acid Residues Severity: Maj cleaning is strongly place.
Balance Tank implemented so Proper cleaning,
N.S likelihood is low sterilization of
hence it is NS. equipment.
Clean potable
water tested for
IS 10500 is
used.
Training has
been provided to
the working staff.
13. Butter Biological : Microbes Likelihood: L Likelihood is very low Proper cleaning, No
Severity: as microbes are sterilization of
Churner High already controlled in Churner.
N.S the step of CIP well in
pasteurization & the place.
churning operation is Personnel
performed in covered Hygiene policy is
vats & sop of CIP is in place.
well in place so it is Microbes if any
non significant. are Controlled in
future step of
cooking.
Chemical: Caustic & Likelihood: L As the SOP of CIP well in No
Acid Residues Severity: Maj cleaning is strongly place.
implemented so Proper cleaning,
N.S likelihood is low sterilization of
hence it is NS. equipment.
Clean potable
water tested for
IS 10500 is
used.
Training has
been provided to
the working staff.
14. Butter In Biological : Microbes Likelihood: L Likelihood is very low Proper cleaning, No
Severity: as microbes are sterilization of
trolley High already controlled in Butter Trolley.
N.S the step of Personnel
pasteurization & the Hygiene policy is
transfer of butter in place.
through butter trolley Microbes if any
is performed in are Controlled in
covered condition & future step of
cleaning of trolley is cooking.
well in place so it is
non significant.
Chemical: Caustic & Likelihood: M As the SOP of Proper cleaning, No
Acid Residues Severity: Maj cleaning is strongly sterilization of
implemented so Butter Trolley.
N.S likelihood is low Clean potable
hence it is NS. water tested for
IS 10500 is
used.
Training has
been provided to
the working staff.
 Physical : Metal, Likelihood: L It is non significant as G.M.P in place. No
Jwellery Severity: the operation is butter Metal & Jwellery
Minor is transferred in policy is in
N.S covered trolleys & strictly in place.
metal policy is in
place so likelihood of
metal is very low.
15. Butter Melting Biological : Microbes Likelihood: L Likelihood is very low Proper cleaning, No (OPRP)
Severity: as microbes are sterilization of
Vat High already controlled in Butter Melting
N.S the step of Vat.
pasteurization & the CIP well in
butter melting place.
operation is Personnel
performed in covered Hygiene policy is
vats & sop of CIP is in place.
well in place so it is Microbes if any
non significant. are Controlled in
future step of
cooking.
Chemical: Caustic & Likelihood: M As the SOP of CIP well in No
Acid Residues Severity: Maj cleaning is strongly place.
implemented so Proper cleaning,
N.S likelihood is low sterilization of
hence it is NS. equipment.
Clean potable
water tested for
IS 10500 is
used.
Training has
been provided to
the working staff.
Physical : Metal, Likelihood: L It is non significant as G.M.P in place. No
Jwellery Severity: the operation is butter Metal & Jwellery
Minor melting is performed policy is in
N.S in covered vats & strictly in place.
metal policy is in Melting is done
place so likelihood of by covering the
metal is very low. Vat by Lid.
16. Pre Biological : Microbes Likelihood: L Likelihood is very low Proper cleaning, No
Severity: as microbes are sterilization of
Stratification High already controlled in Butter Melting
Tank N.S the step of Vat.
pasteurization & the CIP well in
pre stratification place.
operation is Personnel
performed in covered Hygiene policy is
tanks & sop of CIP is in place.
well in place so it is Microbes if any
non significant. are Controlled in
future step of
cooking.
Chemical: Caustic & Likelihood: M As the SOP of CIP well in No
Acid Residues Severity: Maj cleaning is strongly place.
implemented so Proper cleaning,
N.S likelihood is low sterilization of
hence it is NS. equipment.
Clean potable
water tested for
IS 10500 is
used.
Training has
been provided to
the working staff.
Physical : Metal, Likelihood: L It is non significant as G.M.P in place. No
Jwellery Severity: the pre stratification Metal & Jwellery
Minor operation is policy is in
N.S performed in covered strictly in place.
tanks & metal policy is Stratification is
in place so likelihood done in covered
 of metal is very low. Vat.
17. Ghee Biological : Likelihood: L Likelihood of Maintaining the CCP
Microbes, yeast & Severity: microbes are very low temperature at
Cooking molds Serious but if the cooking 108+ 1ºC to kill
Kettle S operation is not all the microbes
performed in & remove the
controlled moisture.
temperature than the Proper cleaning,
possibility of moisture sterilization of
will remain there in Ghee Cooking
the final product Kettle.
which will help the CIP well in
microbes, yeast & place.
mold to grow again & Personnel
hence will reduce the Hygiene policy is
self life, so it is in place.
significant.
Chemical: Caustic & Likelihood: M As the SOP of CIP well in No
Acid Residues Severity: Maj cleaning is strongly place.
implemented so Proper cleaning,
N.S likelihood is low sterilization of
hence it is NS. equipment.
Clean potable
water tested for
IS 10500 is
used.
Training has
been provided to
the working staff.
Physical : Metal, Likelihood: L It is non significant as G.M.P in place. No
Jwellery Severity: the ghee melting Metal & Jwellery
Minor operation is policy is in
N.S performed in covered strictly in place.
kettles & metal policy Ghee Cooking is
is in place so done in covered
likelihood of metal is Kettle.
very low.
18. Ghee Settling Biological : Microbes Likelihood: L Likelihood is very low Proper cleaning, No
Severity: as microbes are sterilization of
Tank High already controlled in Ghee Settling
N.S the step of Tank.
pasteurization & CIP well in
cooking. Ghee settling place.
operation is Personnel
performed in covered Hygiene policy is
tanks & sop of CIP is in place.
well in place so it is
non significant.
Chemical: Caustic & Likelihood: M As the SOP of CIP well in No
Acid Residues Severity: Maj cleaning is strongly place.
implemented so Proper cleaning,
N.S likelihood is low sterilization of
hence it is NS. equipment.
Clean potable
water tested for
IS 10500 is
used.
Training has
been provided to
the working staff.
Physical : Metal, Likelihood: L It is non significant as G.M.P in place. No
Jwellery Severity: the ghee settling Metal & Jwellery
Minor operation is policy is in
N.S performed in covered strictly in place.
tanks & metal policy is Ghee settling is
in place so likelihood performed in
of metal is very low. covered tank.
19. Clarification Biological : Microbes Likelihood: L It is non significant as Proper cleaning, No (OPRP)
Severity: the likelihood of sterilization of
 High occurrence is very low Clarifier.
N.S due to the prior CIP well in
operation of cooking. place.
Personnel
Hygiene policy is
in place.
Chemical: Caustic & Likelihood: M As the SOP of CIP well in No
Acid Residues Severity: Maj cleaning is strongly place.
implemented so Proper cleaning,
N.S likelihood is low sterilization of
hence it is NS. Clarifier.
Clean potable
water tested for
IS 10500 is
used.
Training has
been provided to
the working staff.
20. Ghee Storage Biological : Microbes Likelihood: L It is non significant as Proper cleaning, No
Severity: the likelihood of sterilization of
Tank High occurrence is very low Ghee Storage
N.S due to the prior Tank.
operation of cooking CIP well in
& sop of cleaning well place.
in place. Personnel
Hygiene policy is
in place.
Chemical: Caustic & Likelihood: M As the SOP of CIP well in No
Acid Residues Severity: Maj cleaning is strongly place.
implemented so Proper cleaning,
N.S likelihood is low sterilization of
hence it is NS. equipment.
Clean potable
water tested for
IS 10500 is
used.
Training has
been provided to
the working staff.
Physical : Metal, Likelihood: L It is non significant as G.M.P in place. No
Jwellery Severity: the ghee storage Metal & Jwellery
Minor operation is policy is in
performed in covered strictly in place.
tanks & metal policy is Ghee Storage is
in place so likelihood performed in
of metal is very low. covered tank.
21. Inspection & No hazards are
involved in this step
Testing as this step is
specifically designed
to detect any non
conformity in the
product.
22. Cooling No hazards are
involved in this step
as this step as the
cooling operation
doesn’t have the
probability of any
hazards inclusion.
23. Packaging Biological : Microbes Likelihood: L It is non significant as Personnel No
Severity: the likelihood is very Hygiene policy is
High N.S low because of in place.
automated process &
sop of cleaning in
place.
 Physical : Metal, Likelihood: L It is non significant as G.M.P in place. No
Jwellery Severity: the packaging is done Metal & Jwellery
Major by automatic policy is in
N.S packaging machines strictly in place.
& metal policy is in
place so likelihood of
metal is very low.
24. Ghee No hazards are
involved in this step
Granulation as the ghee
granulation is done
in packed ghee in a
proper hygienic
condition of the
room.
25. Finished No hazards are
involved in this step
Goods Stores as the storage is
done in pallets and
in a proper hygienic
condition of the
stores area.
26. Dispatch Physical : Dust Likelihood: L Likelihood is very low G.M.P in place. No
Particles, Metal, Severity: as the material is kept Ensuring the
Extraneous Matter Major in covered condition cleanliness &
N.S so it is NS. condition of he
Truck.

HAZARD ANALYSIS USING DECISION TREE OF GHEE

Flow chart Types Hazards Risk Severit Justificati Preventive Q1 Q Q Q Q5 Is it a
steps/ of (H/M y(Critic on Measure(s) 2 3 4 CCP?
ingredients hazard /L) al/ Y/N
s Serious
/Major/
Minor)

Filtration Physic Metal, High Major Improper Maintain the Y Y Y CCP

al Stones, Filtration Sieve size:
Husk, allows 80 mesh.
Extrane extraneou Change of
ous s matter nylon sieve
matter to go to cloth &
etc the next assurance of
phase & its
hence to cleanliness.
the final
milk
which
could
cause
harm to
could
harm the
internal
organs on
consumpt
ion.
Cream Biolog Pathoge High Critical Pathogen Calibration Y Y Y CCP
Pasteurizati ical nic ic of
on Microbe microbes Thermomet
s on er, assembly
consumpt & condition
ion can of
cause pasteurizer.
health
hazards,
food
poisoning
& early
deteriorat
ion of the
cream.
Ghee Biolog Pathoge High Critical Pathogen Calibration Y Y Y CCP
Cooking ical nic ic of
Microbe microbes Thermomet
 s on er, assembly
consumpt & condition
ion can steam line
cause
health
hazards,
food
poisoning
& early
deteriorat
ion of the
Ghee.

OPRP PLAN TABLE/ WORKSHEET FOR GHEE

Step / Hazard Control Monitoring Corrective Action

Input Measure
What Where How When Who

1. Chilling Biological- Chilling In raw milk By temp. Twice in a Chemist Check the chilled
of raw milk microbes Chilling temp. of temp. silo indicator shift water valve and chilled
raw milk to be water temp.
maintained Do manual cleaning
below 8 deg. c /CIP of chiller

Physical –
nil - - - - - -

Chemical- Follow SOP of Cleaning In raw milk By ph paper After every Chemist Check the strength of
detergent CIP and and chiller CIP CIP solution and
,sanitizer sanitization sanitization sanitizer . check the
residue quality of water
Butter Biological- Maintain melting Butter In butter By temp. Every batch Ghee/butter Check the steam pr. ,
melting microbes temp. of butter melting melting vat indicator operator condition of steam
melting temp. control system, do
manual cleaning of
melting vat
Chemical – Follow SOP of Cleaning In butter Visually by After every chemist Check the strength of
detergent CIP/manual and melting vat ph paper cleaning I CIP solution and
sanitizer cleaning and sanitization sanitizer . check the
sanitization quality of water.

Physical- nil - - - - - -

3. Ghee Biological- Proper Cleaning In ghee Visually /by After Microbiologi Check the strength of
clarification microbes cleaning/sanitiza and clarifier swab test cleaning st CIP solution and
tion of ghee sanitization sanitizer . check the
clarifier quality of water, take
swab of the melting vat
after cleaning

Chemical- Follow SOP of Cleaning In ghee Visually by After every Chemist

residue of CIP/manual and clarifier ph paper cleaning
detergent cleaning and sanitization Check the strength of
/sanitizer sanitization CIP solution and
sanitizer . check the
quality of water

Physical – Maintain Clarification In ghee By temp. Every batch Ghee

Denatured clarification temp temp. clarifier indicator operator
proteins 70-75 deg.c
particles
 HACCP PLAN TABLE/ WORKSHEET FOR GHEE

Step Hazard Control CCP Critical Monitoring Corrective Verifica Records

/ Measur Limit Action tion
Input e What Where How When Who Who &
When

Filtrati Physical Nylon CCP Physical Sieve In RMRD By Hourly Line Correction: Who- Sieve size
on : Sieve/ condition size in checki operat Re filtration of Manager check
Metal, filter of the receiving ng the or . raw milk. Milk record.
Stones, cloth of Nylon area of conditi Procure
Husk etc 80mesh sieve raw milk. on of C.A: Change ment,
cloth & nylon of nylon sieve Q.A.
Mesh sieve cloth & Manager.
size 80 cloth. assurance of
mesh its cleanliness. When-
Every
week

Hourly
Crea Biologic Time & CCP Pasteuriz Pasteu In By Proces Correction: Who- Process log
m al: Tempera ation rizatio Productio calibra s Re Prod. In sheet
Paste Pathoge ture of Temp: n Time n during ted operat pasteurization charge,
urizati ns & heating 79±3ºC . & processi temp. or . of raw milk. Q.A. In
on microbial of milk Time: 15 Temp. ng. indicat charge.
load followed sec. ors of C.A:
by Chilling Pasteu Calibration of When-
immediat Temp: rizer & Thermometer, Every
e 5ºC time to assembly & week.
cooling. time condition of
cross pasteurizer.
checki Condition of
ng by steam control
calibra valve , Steam
ted lab pr. Gauge .
thermo
meter.
 Ghee
Ghee Biologic Tempera CCP Cooking Cookin In Ghee By Every Ghee Correction: Who- &butter
Cooki al: ture of Temp: g processi calibra batch operat Re cooking if Prod. In logsheet
ng Pathoge cooking 108+ Time. ng. ted or . ghee. charge,
ns & of butter 1ºC. temp. Q.A. In
microbial to ghee. indicat C.A: charge.
load ors of Calibration of
Ghee Thermometer, When-
cookin assembly & Every
g condition week.
kettle. steam line.
cross Steam control
checki valve , steam
ng by pr.
calibra
ted lab
thermo
meter.

ON SITE VERIFICATION OF FLOW DIAGRAM

Following members of HACCP team have verified the flow diagram of Chhach
manufacturing on site on date.

S. No. Name of Team member Designation Signature

1. Mr.Balvir Singh General Manager

2. Mr.Sunil Singhal Deputy General Manager

3 Mr.U.S Rajput Functional Manager

4. Mr.Manoj Kr. Sharma Quality Control Manager

Mr.Sunit Nidhi Manager P&A

5.

6. Mr.Sushil Saxena Manager Sales

7. Mr.Ravindra pal Singh Mgr Milk Procurement

8. Mr.R.P Rathi Mgr Purchase/Store

9. Mr.Bhojraj Singh Electrical Foreman

10. Mr.Manoj Mishra DPM

11. Mr.Balvir Singh General Manager