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Pure Curd Supply Chain: An Indian Case on Modern Food Safety Management

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DOI: 10.4018/978-1-4666-9795-9.ch006

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Chapter 6
Pure Curd Supply Chain:
An Indian Case on Modern
Food Safety Management

Rajneesh Mahajan
Apeejay School of Management, India & Delhi Technological University, India

Suresh Garg
Delhi Technological University, India

P. B. Sharma
Delhi Technological University, India

ABSTRACT
The modern food safety management comprises of ISO 22000:2005. It has modified the hazard analysis
critical control point (HACCP) by embedding food safety management. It has created a standardized
management system. The objective of current chapter is to endow a systematic approach for the ground
level implementation of ISO 22000 in Indian pure curd supply chain management. The chapter is pre-
pared utilizing combination of qualitative research and case study method. A case of Milsh Dairy Ltd.
(MDL, organisation’s name is disguised) was discussed to shed light on ISO 22000 features, comparative
analysis between HACCP and ISO 22000. The research is limited to professional pure curd manufactur-
ing sector. Authors have adopted the research methodology which can be applied to other sectors also.

INTRODUCTION

India is the largest milk producer in the world. More than 15 million milk producers sell their milk to
44,246 dairy cooperatives nationally. The collected milk is processed in 177 district co-operative unions
and marketed by 22 state marketing federations cum dairies, ensuring a better milk quality (Animal and
Dairy Tech Asia, 2013). The milk and milk products are customarily a crucial source of human nutrition.
Milk products comprises of fresh milk, milk based products such as butter, butter milk of lassi, pure
curd or yogurt, cheese, cottage cheese etc. The pure curd or yogurt is a crucial source of nourishment in
India, and rest of world. Tamime et al. (2004), Valli et al. (2005) talked about consumption of yoghurt

DOI: 10.4018/978-1-4666-9795-9.ch006

Copyright © 2016, IGI Global. Copying or distributing in print or electronic forms without written permission of IGI Global is prohibited.
 
Pure Curd Supply Chain

and it’s by products showing continuously increasing trend. Roughly four out of every five fast food
advertisements (79%) associated their product with fruit. Dairy products (53.3%) and sugared drinks
(52.6%) included associations with fruit in more than half of their advertising. Common examples in-
clude fruit-flavoured yogurt products (Castonguay et al. 2013). Regular intake of pure curd produced
by lactobacillus delbruceckii ssp. bulgaricus and streptococcus thermophilus looks effective both in
prevention and treatment of various illnesses in human being like gastrointestinal, hypercholesterolemia,
etc. (Saeed et al,2013).
The objective of current chapter is to endow a systematic approach for the ground level implementation
of ISO 22000 in Indian pure curd supply chain management. The chapter is prepared utilizing combina-
tion of qualitative research and case study method. A case of Milsh Dairy Ltd. (MDL, organisation’s
name is disguised) was discussed to shed light on ISO 22000 features, comparative analysis between
HACCP and ISO 22000
The chapter is started with introduction of topic. Then, elaborates HACCP practice, explains ISO
22000 and shed light on comparative analysis of HACCP and ISO22000. It is followed by a case of
MDL and suggestion for ISO 22000 implementation process.

HAZARD CRITICAL CONTROL POINTS (HACCP)

The food sector faces numerous challenges concurrently, to supply better food quality and safe food at
affordable prices in sufficient quantity, to cater greater demand from growth of population. There are
three issues that stand out from a health angle like first, ensuring food safety from chemical or biologi-
cal food contamination. The second is organic food preferred by consumers (Dangour et al., 2009). The
third, impact of food offered general health of consumers (McCarthya et al., 2013). HACCP is a food
safety management system (FSMS) that is recognized in the international food safety community as a
worldwide guideline for controlling food borne safety hazards (Kafetzopoulos et al., 2013). The indus-
trialised countries reported a progressing trouble of food borne illness (Flint et al., 2005; Anonymous,
2007). Ultimately all the efforts can support in achieving quality and safety.
The major landmark strategy in the food sector is introduction of HACCP (History of HACCP, 1959).
The Pillsbury Company joined the programme as contractor to produce food for astronauts in 1959.
HACCP was first presented 1971. It was based on three principles. HACCP-based ingredients and product
specifications were completed in 1975. In 1985, interest in HACCP was restored, when a subcommittee
of the Food Protection Committee of NASA issued a report on microbiological criteria. They recognised
the advantages of HACCP over traditional quality procedures in food safety management, progressive
food companies. The present status of HACCP i.e. Seven Principles are shown in figure 1.
In the figure 2, the six benefits pertaining to the HACCP are depicted.
The HACCP is a globally recognised as a FSMS. To introduce the HACCP to Indian processed
food sector (PFS), monetary support in the form of grant is being offered by the Government of India
(GOI). The Ministry of Food Processing of Industries (MOFPI, 2012) is offering financial incentives
for the benefit of the PFS. To inspire the food processers for adoption of food safety and quality assur-
ance mechanisms such as HACCP, good manufacturing process (GMP) and good hygienic practices
(GHP). MOFPI makes efforts to organize food operators to face the global competition as per guidelines

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Pure Curd Supply Chain

Figure 1. HACCP Principles

Note: CCPs implies critical control points

Figure 2. Benefits of HACCP

of WTO. Therefore, Indian processed food sector can adhere to stringent hygiene and quality norms. It
will improve product recognition by foreign buyers and maintain sector technologically abreast to best
practices. The pattern of financial assistance, up to 50% of the total cost of the project towards imple-
mentation of quality management system including HACCP, GMP and GHP in general areas and up to
75% in difficult areas. The absolute ceiling will remain $20,000 and $30,000 respectively ($@Rs. 50)
(Ministry of Food Processing Industries, 2012).

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Pure Curd Supply Chain

FOOD SAFETY CONTROL SYSTEM

The prerequisite for deployment and implementation of HACCP philosophy is to introduce sanitation
standard operating procedures (SSOP) and standard operating procedures (SOP) in processed food sec-
tor. Therefore, Food Safety and Standards Act (2006) have made provisions in governing food sanitation
requires that food HACCP, GMP and GHP ought to be implemented in Indian PFS. Indian viewpoint,
the global harmonisation of food regulations poses many issues and challenges in improving the overall
food and nutrition security of the population and the food trade within as well as outside the country
(Prakash, 2013).With a growing population of over 1.2 billion, Indian food law is intently focused on
strengthening food security, and increasingly on promoting nutrition and food safety. The resultant food
safety control system is three fold in India. It comprises of HACCP, GMP and GHP (figure 3).
FASSI laid-down nine SOPs for processed food manufacturing and food processing sector for imple-
mentation of HACCP in India. These SOPs should be in black and white and describes daily procedures.
It shall be conducted before and during procedures to prevent product contamination or adulteration. In
addition, the SOPs also include the frequency at which each procedure will be done. SOPs in HACCP,
GMP and GHP should be agreed and signed by an official with overall authority at plant. Even for miner
alteration, initiation and modification, the SOPs must be signed. The microbiological testing includ-
ing the total aerobic count, coliform and E.coli, is often being done to ensure that each particular SOP
achieves an tolerable level of performance in controlling microbial hazard. Table 1 is depicting SOP for
food manufacturers, processed food processors and food services in India.
On the above mentioned lines other SOPs can be developed separately for storage, delivery, testing,
measuring, customer complaints, product recall and documentation.

Figure 3. Food safety control system

Table 1. SOPs for food manufacturers, processors and services

Standard Operating Procedures (SOPs) for food manufacturers

Food Manufacturers and Processors
S.No. SOP for Sanitation Management
1 Factory, Building etc.
2 Cleaning of tools and containers
3 Sanitation management of employees
4 Administration of chemicals and detergents
5 Waste product treatment process
6 Man in charge for sanitation management
Food Services
S.No. SOP for Sanitation Management
1 Factory, Building etc.
2 Cleaning of tools and containers
3 Sanitation management of employees
4 Administration of chemicals and detergents
5 Waste product treatment process
6 Man in charge for sanitation management

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Pure Curd Supply Chain

GOODS MANUFACTURING PROCESS (GMP)

GMP is defined as a bundle of feasible methods and practices that ensure quality manufacturing system.
It can provide consistent manufacturing by controlling product quality through qualitative and conformity
assessing criteria. It has a clear goal as desired by International, national legal authorities specification,
marketing channels and consumers of the product. The planned outlay is desired to ensure that a food
handling facility is suitably constructed to offer safe and quality food. This may be stating the obvi-
ous but the lack of effective GHP and GMP has often been overlooked (Jackson, 2006). The advance
manufacturing techniques are used by production plants for performing tasks related to quality assurance
systems such as GMP, GHP and HACCP (Konecka-Matyjek et al., 2005).
Key conditions of GMP are as follows. The current GMPs consist of seven subparts. The requirements
are purposely general to allow individual variation by manufacturers to implement the requirements in
a manner that best suit their needs (FAO, 2004).

GOOD HYGIENE PRACTICE (GHP)

Good hygiene practice consists of procedures and processes that revisit the processing environment to its
original condition, maintain building and equipment in efficient operation, control of cross-contamination
during manufacturing. GMP and GHP as laid down in the relevant code of practice as seen in figure 4
(IFST, 1991; Grigg and McAlinden, 2001).

INTERNATIONAL STANDARD ORGANIZATION

International Standard Organization (ISO 22000:2005) combines main constituents to make certain food
safety along with the processed food supply chain management (PFSCM). ISO 22000 ensures the ef-
fective production of safe products fit for human consumption through three major prerequisites, a).Pre
Requisites Programs b).Operational Pre Requisite Programs (O-PRPs) and c).Detailed and implementable
HACCP Plan.

Figure 4. Eight principles of GHP

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Pure Curd Supply Chain

Benefits of ISO22000
• Most advantageous allocation of resources within PFSCM firm.
• Valuable communication with all the business associates such as suppliers, consumers etc.
• Spotlight on the prerequisite programmes, hygiene measures, planning of preventive actions to
minimise failures.
• Better Paper work for all procedures.
• Establishment of trust in system and procedure.

Advance and new ISO22000, Food safety management systems is needed for PFSCM firms’ aims at
the implementation of the principles of HACCP from the food chain organisations to offer safe food to
the consumers.
ISO22000 specifies the requirements of a FSMS, surrounded by the range of food firms involved in
the PFSCM from farmers to catering businesses. ISO22000 creates a uniform and homogeneous plat-
form of requirements, acceptable to authorities globally. ISO22000 was proposed in 2005. Categories
of food organisations

1. The directly involved with PFSCM firms such as food producers, processors, food additives manu-
facturers, raw and auxiliary raw materials for the food industries, food services, food distributors,
distributors, carrying and forwarding agents, logistics service providers and warehousing companies.
2. The indirectly involved with PFSCM such as suppliers of raw materials, equipment, cleaning and
packaging materials and other materials that come directly or indirectly into contact with food
(Arvanitoyannis & Tzouros 2006, Varzakas et al. 2008).

ISO 22000 FSMS has been designed to overcome the problems that can be encountered when imple-
menting following procedures:

• Lack of strong pre-requisite programmes.

• Complex and unmanageable systems with many CCPs, resulting from a misunderstanding of the
role of prerequisite hygiene programs (PRPs) and an inability to conduct proper hazard analysis.
• Weak monitoring and corrective actions due to poor training and verification procedures.
• Excessive documentation and lack of focus due to over-complex systems.
• Poor validation and verification due to lack of expertise.
• Over complication of HACCP implementation.

After acquiring an understanding of food safety principles, firm can have the commitment and resources
to implement food safety measures. This may lead to form an excellent Food Safety Management System.

COMPARATIVE ANALYSIS OF HACCP AND ISO22000

It is true that neither ISO22000 nor HACCP can function independently to achieve the herculean objective
of food safety in food supply chain management. Thus, it is marriage two can able to offer consumers
100% hazard free food experience worldwide. In this direction it is necessary to understand the differ-
ences between two HACCP and ISO 22000 (see table 2).

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Pure Curd Supply Chain

Table 2. Comparative analysis of HACCP and ISO22000

Hazard Analysis Critical Control Points HACCP
HACCP is based on seven principles
Implemented is in isolatation
Well documented standard operating procedures (SOPs) desired
Implementable integrated food safety procedures
HACCP is qualitative in nature
HACCP ensures following safety control procedures:
a) Prerequisite Programs (PRPs)
b) HACCP plan
ISO 22000 Food Safety System for PFSCM
Improved food safety procedures
Implementation on bases of process management
Food safety plan required to be integrated with SOPs
Offer food safety system designed, operated and continuously
updated
ISO 22000 has quantitative targets based system. It offers a hazard
free food
ISO 22000 standard compulsory deploy following procedures at
control level, because of this its created a three-level safety control
hierarchy, namely:-
a) PRPs
b)Operational Prerequisite Programs (O-PRPs) c) HACCP plan

A CASE OF PURE CURD MANUFACTURING

Milsh Dairy Ltd. (MDL, organisation’s name is disguised), is India’s dairy products manufacturing and
marketing firm turnover of US$ 2.5 billion annually. Its daily milk procurement is around 12 million
litres per day from more than 12000 village milk cooperatives and 3.18 million milk producers. The
objective of MDL is to provide remunerative returns to the milk producers and serve the interest of
Indian consumers by providing excellent quality and safe products which are good value for money. Its
success has been emulated in India.
MDL product range comprises milk, milk powder, pure curd, ghee, butter, cheese; ice-cream etc. MDL
has received numerous awards for its consistent adherence to quality, customer focus and dependability.
Pure curd is prepared from purest, freshest pasteurized milk and it is free from added sugar. It does
not contain any preservatives. Pure curd is prepared from certified and selected bacterial culture which
gives excellent curd. It is hygienically processed and packed in a reusable plastic tub which is free from
possible adulteration. It is high on nutrition and taste. MDLs have built an excellent and strong deal
network in India. It operates through 48 sales offices and has a dealer network of more than 3000 dealers
and million retailers across India.
The pure curd supply chain is temperature sensitive in nature. Pure curd supply chain required to
optimal temperature below plus six degree celsius. Therefore, immediately after its production settling
down as curd, its temperature must be maintained below plus six degree celsius. It has to be maintained
right from warehousing of firm, during logistics, at distributors, retailers and even at consumer home
before its final consumption. If desired temperature is not maintained then pure curd may become sour,
smelly and bad bacteria formation in the product can convert it to most harmful for human consump-
tion. To cater to Delhi and national capital region (NCR), MDL has plant located at Manesar, Gurgaon
in India. The pure curd plant is the most advanced one installed in this production facility of MDL. The
most of machines in dairy belong to Tetra pak. It is one of the best manufacturer of dairy equipment.
This also provides a guarantee that MDL is deploying best of equipment to produce pure curd.

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Pure Curd Supply Chain

A Typical Supply Chain of MDL in Delhi, India

The pure curd is produced through implementing the HACCP. There is tremendous scope of implement-
ing the ISO 22000 in the plant. That will further reduce the possible of any sort of food hazards and this
approach leads to the comprehensive food safety management.
In the section 4, the pure curd or yogurt manufacturing process is explained. It has 11 steps depicted
in figure 6. A proposed plan for implementation of ISO 22000 is explained. Table 4, table 5 elaborates
the HACCP for Pure curd Preparation Plan and Operational prerequisite programs (O-PRPs) for Pure
curd production.

PURE CURD MANUFACTURING PROCESS

Pure curd or Yogurt is classified as dairy item and prepared by fermentation of fresh milk in combination
with the addition of a desirable culture or starter or Khatta or Jaman and coagulation. Milk used comes
from various animals such as cows and buffaloes in India. The milk fat and total solid composition is

Table 4.Operational prerequisite programs (O-PRPs) for pure curd preparation

Hazard
O-PRPs Measures Critical Parameters Limits Strategy
Control
Step1. Fresh Milk Periodic verification Aflatoxin (C) Toxin presence >0,05 mg/kg Discussion with
Receipt at MDL of suppliers Heavy metals Pb presence >.0,02 mg/kg Suppliers
plant conformance (C) Dioxins presence >3 pg/g of Supplier rejection
Dioxins (C) Staphylococcus milk fat
Microbial count >10 cfu/g
growth (B) Bacillus cereus
count
Listeria count
Salmonella count
Step2. Milk Periodic verification Aflatoxin (C) As per O-PRP 1 As per O-PRP Discussion with
Powder Suppliers of suppliers Heavy metals Antibiotic presence 1 suppliers
delivered at MDL Conformance (C) Supplier rejection
Plant Dioxins (C)
Microbial
growth (B)
Antibiotics (C)
Step3. Raw milk Process control Microbial Temperature/time >4°C for >4 Control measure
and powder growth (B) period hours as per
storage CCP 2
at MDL Plant
Step4. Logistics Process control Microbial Temperature/Time >6°C for> 8 Finished product
from Plant to growth (B) period hours withdrawal
warehouse and
then distributors
Step5. Retailers Periodic verification Microbial - Finished product
of finished products growth (B) recall
status Discussion with
retailers

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Pure Curd Supply Chain

usually 10 percent higher than original milk, while pH varies between 4-4.4. The product is packaged
in plastic polystyrene cups and during preservation, temperature below plus 8°C is maintained until its
expiration date 15 days from the production date in India (Codex, 2003). Pure curd can be consumed
by consumers of all ages, from young to elderly people. Dairy products are delivered to end consumers
through retailers. They are categorized into large supermarket, local retailers, smaller stores, kiosks,
canteens, food catering services, hotels etc. The storage and preservation processes of pure curd are the
crucial task for food supply chain management. Figure 5, shows a typical pure curd or yoghurt produc-
tion process.
Pure curd or yogurt is ready and stored under refrigeration below 6°C temperature to keep its quality
intact (Arvanitoyannis & Mavropoulos, 2000, Council of European Communities - CEC, 1992). Sandrou
and Arvanitoyannis, 2000, cold chain maintenance prevent bacteria growth. The finishing product is
distributed with 24 hours of production. The pure curd is loaded in trucks, transported and distributed
to the retailers under proper cold chain (Codex, 2003).
The comprehensive scheme is adopted by the ISO 22000 standard based on the application of process
management principles. A number of management philosophies, like Total Quality Management and
Six Sigma, are based on these principles (Llore´ns-Montes & Molina, 2006). Deming gave Plan-Do-
Check-Act (PGDA) for an effective implementation of process management.

Figure 5. MDLs pure curd or yogurt supply chain

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Pure Curd Supply Chain

Figure 6. Manufacturing of pure curd or plain yogurt

DISCUSSIONS AND CONCLUSION

ISO 22000 standard introduction is a step ahead to achieve food safety objective in a professional man-
ner. ISO2007, over a million ISO 9001 and ISO 14001 certificates were awarded at the end of 2005-
2006 worldwide. The most of food manufactures, marketing and food supply chain management firms
have taken a step further to adopt food safety system through implementing ISO 22000 with HACCP.
is standardized management systems and a certification achieving practice developed . In this paper, an
attempt is made to achieve objective through briefly explaining role of HACCP, defining and explaining
ISO22000 system, drawing a comparative analysis between HACCP and ISO 22000. A case of MDL is
utilized to explain the step by step process of manufacturing of pure curd. A clear cut plan of food safety
was introduced through proposing HACCP plan and ISO 22000, Operational prerequisite programs (O-
PRPs) for Pure curd production at MDL.

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Pure Curd Supply Chain

Table 3. HACCP for pure curd preparation

Hazard
Production Stages Measures Critical Parameters Limits Strategy
Control
Step1 Fresh Milk Receipt at Accept the Microbial Total colony count >105 cfu/g Rejection of raw
MDL plant Fresh Milk if its growth (B) Antibiotic presence >4* 105 cfu/g milk
Temperature > Antibiotics
4 °C (C)
Step2 Milk Storage at MDL Allowed upto Microbial Total colony count >105 cfu/g (fresh Rejection of fresh
Plant declared capacity growth (B) milk) milk
Step3 Processing: Heat Process Control Pathogens Temperature/Time <75°C for 20 Procedure stop –
Treatment at MDL Plant (B) period seconds restart
heat treatment
Step4 Adding Acceptance Microbial Coliform count >1 cfu/g Rejection of
Culture in the microbiology control of starter growth (B) Yeasts count >10 cfu/g starter
lab of MDL Plant culture ingredients Non-vital Moulds count >1 cfu/g culture
culture (B) Lactic acid quantity <0.85-95>% ingredients
Step5 Packaging Process Control Foreign Adhesives Any Issue Rejection of
procedure bodies (P) finished
product
Step6 Finished Pure curd Acceptance Microbial Check a sample Any Issue Rejection of
Storage and logistics control of growth (B) finished
outgoing Pure product
curd after settling
24 Hours

Figure 7. Plan Do Check Act (PGDA)

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Pure Curd Supply Chain

LIMITATION

The research paper has deployed a combination of qualitative and case study method to study the food
safety system implementation in a professional manner under managerial scanner. It is a longitudinal
research work and inclined to single product pure curd or yogurt only. It may be due to limited time
available to carry the research on food safety field.

MANAGERIAL IMPLICATIONS

The learning derived from present case study can be applied to rest of processed food sector in ensuring
a comprehensive food safety. This case studies learning can be further applicable other sectors such as
general management, operations research, knowledge management etc.

FUTURE SCOPE OF RESEARCH

It is desired that an empirical study can fill the gap in this regard. There is tremendous scope of empiri-
cal research to be carried out on ISO 22000. An empirical research should be conducted on food safety
system of India using questionnaire.

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ADDITIONAL READING

Mahajan, R., Garg, S. & Sharma, P.B. (2013), Food safety in India: a case of Deli Processed Food Prod-
ucts Ltd., International Journal of Productivity and Quality Management (Inderscience), Vol. X, No.xx,
has been accepted for publication, September, 2013 (In press), (International Journal, ranked in ABDC
Journal Ranking List-Business and Management)
Mahajan,R., Garg,S. & Sharma, P.B.(2013), An Illustration of Logistic Regression Technique: A Case
of Processed Food Sector, International Journal of Business Excellence, has been accepted for publica-
tion, October, 2013(In press), (International Journal, ranked in ABDC Journal Ranking List-Business
and Management)
Mahajan, R., Garg, S., & Sharma, P. B. (2013). A System Dynamic Framework for Identifying Demand
Gaps in Indian Processed Food Sector. International Journal of Intercultural Information Management,
3(4), 324–343. doi:10.1504/IJIIM.2013.059974
Mahajan,R., Theuvsen,L., Garg,S. & Sharma, P.B. (2013), Comparative Study of Indian and German
Food Supply Chain: A case of Tomato Supply Chain, International Marketing and Management Research
Series - Palgrave Macmillan, Published, April 2014.

KEY TERMS AND DEFINITIONS

Dairy Products: Dairy products are categorized as fresh milk, curd, butter, cheese and rest of dairy
cultural products of India like butter milk (lassi), cottage cheese etc.
HACCP: Hazard critical control points (HACCP) is based on following seven principles: Apply
Hazard Analysis, Identify CCPs, Form Critical Limits For CCPs, Establish Monitoring Procedures, Form
Corrective Actions, Establish Verification Procedures and Form Record-keeping Procedures.
Pure Curd Supply Chain: It is defined as the connect among all the pillars of proud supply chain.
It begins with starting from souring of raw material for curd production. It will be delivered at plant,
processing of raw milk takes place, final product is packed and dispatched to warehouses amd from t.
Quality Standards: They are the benchmarked quality standards for food producers.
Total Food Safety Management: It is a comprehensive food safety system contains implementation
of HACCP, GHP, GMP and ISO22000.

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