Food Safety Supervisor – Milk & Milk

Products
Part I- Introduction to Food Safety
Food safety & food safety hazards
Quality Assurance
Quality

Quality is a measure of the degree of excellence of degree of acceptability

by the consumer. It also covers the safety and value for money.
Important components of food quality
1. Food safety
I. Food borne illness
II. Food hazards
III. Food Safety Management System Certification (FSMS)
IV. The Food Safety and Standards Acts, 2006
V. Recent Concerns of Food safety
2. Nutritional Value
3. Sensory Characteristics
Food Safety Hazard

Means biological, chemical or physical agent in food or

condition of food with the potential to cause an adverse health
effect. There are majorly four type of hazard.
Source of contamination throughout food chain
Bacterial Growth
Exercise

What do you understand by hazards and how do you handle it at your end
? Experience sharing in groups
What is the importance of maintaining cold chain in food safety ? What
kind of issues have you resolved due to cold chain failure ? How did you
manage it ?
You can also share relevant case studies or videos here if available.

20-30 mts
Part II
Location, Layout & Facilities
Classification of Dairy Plant
Planning considerations for a dairy plant
& site location
Layout & design of dairy establishment
premises
 Classification of a Dairy Plant
1. Liquid milk Processing Plant
In such Dairy plant, raw milk received at dock is chilled, processed (Pasteurized) and
packed for sale.
This type of plant has low value addition but the liquidity of money is very high.
The liquidity is better because payment for raw milk is done after 7 to 10 days,
whereas realization is either in advance or on the same day.
2. Product manufacturing Dairy Plants:
Raw milk is transformed into value added milk and milk products
It’s advantage is conversion of perishable milk into long shelf life products.
Long shelf life products are also suitable for distinct market.
3. Composite Dairy Plant:
 Dairy plants do have facilities for processing and packaging of liquid milk and milk
products.
 In this way, Dairy plant can be benefited for high liquidity along with the advantage of
increased shelf life and value addition.
 Such milk plants are more viable and sustainable.
Site Location

The criterion, which has foremost

operational important is
minimum cost for procurement, production
and distribution.
Other essential factors which should
favour the location include topography,
shape and size of site,
Availability of water, power and fuel and,
climatic conditions.
Rail and road connectivity Vegetation Stagnant water
growth near near the
Effluent and solid waste disposal. premises surroundings
However due to increased pollution and
industrialization, all sites are not permitted
for industrial work.
Process & Storage Equipment

Characteristics of food contact surfaces of equipment:

Made up of non-corrosive / rust free material
Smooth, free from any grooves
Easy to clean and maintain
Non-toxic and non-reactive
Food grade quality

Generally food grade stainless steel 304 or

316L is preferred.
 Design of Facilities

Dairy plant has to be provided with

required facilities for water supply,
drainage/waste disposal, cleaning
system, personal hygiene, toilets,
humidity, air and temperature
control, lighting and storage of
various materials.

Electrical panel and board should be Proper slope for drainage.

covered
Water Quality for Dairy processes
The specific method adopted for conventional treatment such as
flocculation / coagulation, filtration and disinfection, lime soda softening
process, electro-dialysis, demineralization and reverse osmosis depending
upon product quality requirement.
The specific method adopted for conventional treatment such as
flocculation / coagulation, filtration and disinfection, lime soda softening
process, electro-dialysis, demineralization and reverse osmosis depending
upon product quality requirement.
Treated water quality parameters for use in Dairy processes:

Parameter Quality
TDS < 50.0 mg/ltr
pH 6.5 – 7
Chloride < 30.0 mg/ltr
Turbidity < 1 NTU
Total Hardness < 8 mg/ltr
Exercise

Que 1. What are the factors to be considered while selecting good site for
setting up a dairy plant ? What kind of issues have you observed and
resolved at your current site ?
Que 2. What is importance of designing for your dairy plant ? Identify key
factors responsible for food safety failures while designing a dairy plant ?
Group discussions based on your current experience.
Que 3. How should we develop separate sections in a dairy plant ranging
from highly vulnerable to safest in context of food safety ? Group exercise
and presentation.

30-45 minutes

Jagdamba Laboratory
Part III
Dairy Processes and Equipment's
PART III
MILK PROCESSING & PACKAGING
Clean Milk Production at Farm and DCS level
Raw milk Reception at Dairy Plant
Chilling& Storage of raw milk
Processing
Clarification
Bactofugation
Cream Separation
Standardization
Homogenization
Pasteurization
Packaging (Sachet)
Different types of Milk & Milk Products
Packaging requirements for Milk and Milk Products
Clean Milk Production

Milk
Milk is considered to be the mammary secretion of a healthy animal. Hence
animal health is an important aspect in the production of clean milk. Good
hygiene and sanitation practices would keep it free from bacterial
contamination.
Essential steps for Clean Milk Production At Farm and DCS Level
Give sufficient quantity of feed and drinking water to cattle prior to milking.
Remove accumulated cow dung.
Cattle shall be bathed and if bath is not possible dry cleaning by broom /
duster should be done.
Maintain the cattle clean and healthy.
Clean milk Production

In case animal is under treatment, discard the milk during the withdrawal
period of the treatment. Do not bring the milk to DCS (Dairy Cooperative
Society) / MCC (Milk Collection Centre), if the cattle is suffering from any
disease.
Clean the cattle shed floor either by washing with water or dry cleaning 10
– 15 minutes before milking.
The floor should not be slippery. It should be firm and dry so as to provide
a proper foothold to the animal while rising or standing.
Clean the udder and teats of the cattle by clean (potable) water and wipe
using a dry & clean cloth.
Use separate vessel for washing of udder and teats & for milking.
Clean Milk Production Continue

Teats should be cleaned after sucking, if cattle is letting down the milk by
calf sucking.
Clean thoroughly the milk collection vessel preferably with detergent and
hot water etc. and keep it inverted to dry before milking.
Milker should wash his/her hands with soap to make them clean and germ
free.
Milker should wear clean clothes.
Chewing and spitting with tobacco and smoking should be avoided during
milking.
Milker should not be suffering from any respiratory ailment or contagious
disease.
Clean Milk Production Continue

Milker should not have any open sores or cuts.

Discard the initial milk from all the four teats to minimize the bacterial load.
Flies, hay, husk, dry cow dung cake or other extraneous matter should not
get into the milking vessel.
After milking rinsing of teats in a dis-infective solution (with water, iodophor
etc.) shall be done to avoid post milking infection.
It is good to keep the animals standing for at least half an hour after
milking. Feed may be provided to encourage this.
Avoid use of measures, tumbler etc. in the milking vessel for removing or
to transfer milk from milking pail.
Clarifier

The function of the clarifier is to

remove undesirable milk solids like
dirt, dust, hay, manure, bacteria,
somatic cells and pulverized hair by
the application of centrifugal force.

Bacteria Removing Clarifier

The function of the Bacteria Removing
Clarifier is to remove bacterial spores
present in milk by the application of
centrifugal force. 2-stage Bactofugation can
remove 99.9% bacterial spores and 90%
bacteria from milk.
Cream Separator
The cream separator is a centrifugal equipment that
separates milk into cream and skimmed milk.
Milk Standardization

The separated cream and skim milk are remixed in certain proportions
to make standardized milk as per further process/market requirement.
Different types of milk like Toned, Double toned, Standardized, Full
cream etc. have different standards of Fat & SNF as prescribed by the
FSSAI.

Standardization of Milk for Fat:

1. This can be made by simple Person square method. Only Fat or
SNF can be standardized by this method.

2. Standardization of Milk for Fat & SNF: This can be made by

Algebraic method.
Auto-
3. On line milk standardization: This is achieved by using combination standardization
of online Density-meter and Flowmeter instruments. unit
 Pasteurizer & Homogenizer
Pasteurizer
• Pasteurization (LTLT/HTST) is a process that kills
pathogens in milk.
• This is achieved by heating the milk in the pasteurizer
to a temperature of minimum 72° centigrade, holding it
at that temperature for 15 seconds and then rapidly
cooling it below 5 degree centigrade.
Homogenizer
Homogenization is the process of reducing the fat
globule size below 2 microns so that they float sus-
pended evenly throughout the entire milk solution.
Homogenizer is the equipment used for
Homogenization.
Homogenization is done in two stages. In first stage,
the milk is passed through small openings with
applied pressure of 2500 PSI followed by 500 PSI in
2nd stage to prevent fat globule clumps.
 Crate Washer
Crate washer
A typical crate washer consists of a washing section(s) and a
rinsing section. In these sections the nozzles that are
mounted on the spraying racks will produce the Mechanical
Action of the Temperature Controlled and Chemical Dosed
water. Each washing section has its own reservoir for re-use
of the washing water and for the rinsing section, fresh water
will be used. A transport chain or transport belt will be used to
transport the crates through the machine with a certain
(controllable) speed to meet the Washing Time for a certain
crate/pollution.

Advantages of High Pressure Jet cleaning:

 Reduction in plant down time
 Saves labour cost and space
 Environment friendly as it saves water, reduces
noise pollution & air pollution as there is no
generation of gas, smoke and heat
• Safe to use: Effective cleaning without/less use of
hazardous chemicals with no damage to the
High Pressure Jet cleaning in Crate Washer underlying surface
Different types of Milk& Milk
Products
Different types of Milk& Milk
Products
Different types of Milk& Milk
Products
Different types of Milk& Milk
Products
Exercise

What kind of processes plays the most important part in Food safety ?
How does Clean Milk production at farm level help in reducing the burden
of Food safety at plant level ? Group exercise and experience sharing with
examples.
What is the role of processes like clarification and bactofugation in creating
food safety for processing of value added products ?
What all needs to be done to ensure food safety in batch processes for
making Indian sweets or value added products in small quantities ? Group
exercise
How does food safety requirements varies with change in product mix from
liquid milk processing to processing of fermented milk products and UHT
products ? Group exercise.

30-45 minutes
PART IV
Cleaning & Sanitation & equipment
maintenance
CLEANING & SANITATION AND
EQUIPMENT MAINTENANCE

Cleaning & Sanitation

Food Soils & their removal
Cleaning-In-Place (CIP)
Sanitation/Disinfection
Checks for Cleaning Efficiency
Hygiene station
Equipment Maintenance
Instrumentation in Dairy Sector
Cleaning & Sanitation
Milk is a perfect media for growth of micro-organisms at ambient
conditions and gets easily contaminated once it comes in contact with
un-cleaned equipment and vessels. It is, therefore, essential to clean
& sanitize the equipment in which milk is held during processing.
There are different methods for cleaning:

 Manual
 Semi-automatic
 Automatic

Cleaning-In-Place (CIP)
CIP is the cleaning of Dairy plants without dismantling
equipment/pipes and without altering the production process
configuration.
Checking the efficiency of cleaning by
1. Swab test
2. Rinse test
3. ATP Bioluminescence
Food Soils & their removal
Components Solubility Ease of Change on heating
on surface removal

Sugar Water & acid Easy Caramelization –

soluble more difficult to
clean
Fat Water in- Difficult Polymerization –
soluble, alkali more difficult to
soluble clean
Protein Water- Very Denaturation- much
insoluble, difficult more difficult to
alkali soluble, clean
slightly acid-
soluble
Mineral Variable Easy to Generally easy to
Salts water- difficult clean
solubility,
mostly acid-
soluble
 Sanitation/Disinfection

Why is disinfection necessary?

 Cleaning may not be 100% effective.
 Microorganisms remain on surfaces after cleaning.
 Some of these organisms may be pathogens or
spoilage organisms.
 Disinfection with hot water 90 – 95°C for 5 minutes

Effective sanitation depends on

 Concentration
The main disinfectant :
 Temperature
 Contact time Aldehydes
 Degree of soiling Alcohol
 Water hardness
Iodophor
 pH
Phenolics
Chlorine (Hypochlorite)
 Equipment Maintenance
There are 3 types of maintenance:
1. Corrective/ Break-down maintenance
Corrective maintenance of equipment after equipment break down or malfunction and is often
most expensive. The worn out equipment part can damage other parts and lead to multiple
damage and increase repair/replacement costs. Machine downtime is highest and lead to
production losses as well.
2. Preventive maintenance
It is performed with the intent of avoiding failures, safety violations, unnecessary production
losses, and to conserve original materials of fabrication. The effectiveness of a preventive
maintenance schedule depends on the Root Cause Analysis. The history sheet maintained
also helps in early detection of problems and increased equipment life.
3. Predictive maintenance
This maintenance strategy uses sensors to monitor key parameters within a machine or
system and uses this data in conjunction with analysed historical trends to continuously
evaluate the system health and predict a breakdown before it happens e.g. on-line monitoring
of bowl speed, motor current, flow-rate etc. during operation of Clarifier / Cream separator /
Bacteria removing clarifier.
Maintenance
Pasteurizer maintenance
Periodic inspection of Pasteurizer for leakages and opening of Pasteurizer once in 6 months.
Checking of rubber gaskets i.e. corner gasket, channel plate gasket and end plate gasket when
the Pasteurizer is opened every six months. In case leakages are observed before six months,
it needs to be checked immediately.
Checking of pin holes in PHE plates, block and tie-rod after every 10 years of interval.
Homogenizer maintenance

Homogenizing
1 head Quarterly Valve Seat
Homogenizer Forcer
Impact Ring
2 Oil Changing After 5000 running hours
Exercise

What is the importance of cleaning and sanitizing the dairy plant ? What is
the difference between the two ?
How does you test whether the cleaning and sanitization done at your
plant is sufficient and is effective ?
What are the hazards associated with uncontrolled cleaning and sanitizing
at a dairy plant ? Group discussions
What are the emerging trends in availability of chemicals and sanitizers for
dairy industry ? Discussion

20-30 minutes
PART-V
Personal Hygiene
PERSONAL HYGIENE

Health status, Behavioural &

Personal cleanliness of Plant operators &Visitors
Safety Systems for Dairy industry
Health Status

Personnel known, or believed, to be suffering from, or to

be a carrier of a disease or illness likely to transmitted
through food, shall not be allowed to enter into any food
handling area.
Any person affected, shall immediately report illness or
symptoms of illness to the management and medical
examination of a food handler shall be carried out apart
from the periodic check-ups, if clinically or
epidemiologically indicated.
Arrangements shall be made to get the food handlers /
employees of the establishment medically examined once
in a year to ensure that they are free from any infectious,
contagious and other communicable diseases.
A record of these examinations signed by a registered
medical practitioner shall be maintained for inspection
purpose.
In case of an epidemic, all workers are to be vaccinated
irrespective of the scheduled vaccination.
Format
Behavioural & personal
cleanliness
Behavioural & personal cleanliness
Behavioural & personal
cleanliness
Behavioural & personal
cleanliness
Visitors

Generally visitors should be

discouraged from going inside the food
handling areas.
Proper care has to be taken to ensure
that food safety & hygiene is not getting
compromised due to visitors in the floor
area.
The Food Business shall ensure that
visitors to its food manufacturing,
cooking, preparation, storage or
handling areas must wherever
appropriate, wear protective clothing,
footwear and adhere to the other
personal hygiene provisions envisaged
in this section.
SAFETY SYSTEMS FOR DAIRY
INDUSTRY
Dairy industry involves several hazards. To handling these hazardous
environment following safety systems are very essential.
1. Fire fighting systems: i. Fire hydrant
ii. Fire Extinguishers for different
types of Fires- A, B, C or combination
iii. Fire Sand Buckets
iv. Sprinkler systems
2. Emergency alerting system: i. Smoke Detectors of optical and heat
sensing type
ii. Ammonia Detector
3. Emergency Declaring systems i. Emergency Siren
ii. Manual Call Points
4. Emergency Indicating systems – Cold room bells
5. Escape routes
6. Assembly point
7. Wind sack
8. First Aid systems i. Ambu bag
ii. First Aid box
9. Personal Protective Equipment’s (PPEs)
10. Emergency Control Room
Exercise

What are the possible threats in food safety if personal hygiene is not
supervised and controlled well ? Experience sharing
Personal hygiene is a mindset and can not be taught ? Debate

20-30 minutes
PART-VI
Milk & milk Products transportation,
storage and distribution
Milk & Milk Products Transportation
The vehicles used to transport milk and milk
products must be maintained in good condition
and kept clean.
Ensure that as much as possible the required
temperature shall be maintained throughout the
supply chain from the place of procurement or
sourcing till it reaches the end consumer
including chilling, transportation, storage etc.
Milk and milk products while in transport in
packaged form or in containers shall maintain
the required temperature. Road Milk Tanker
Whenever frozen food / raw materials are being
used / handled / transported, proper care
should be taken so that defrosted / thawed
material are not stored back after opening for
future use.

Refrigerated vehicle for transportation of

Dairy products like Ice-cream, Butter, Cheese
and Paneer
Cold Chain
Storage

No space between wall and Proper stacking of raw

stack may lead to material away from wall
unhygienic conditions &
pest infestation
Stock Management
PART-VII
Milk & Milk Products Testing
MILK & MILK PRODUCTS
TESTING

Sampling
Quality Testing Parameters
Microbiological standards for Milk & Milk Products
Safety Testing Parameters
Basic Milk Analysis
Quality Testing Parameters

Raw Milk
Milk when received from different
chilling units & societies is
measured & sample is drawn for
quality testing. A small bottle of milk
is also given by the centres along
with the Chalan data to compare
the result of fat, SNF, acidity. This
helps in determine whether
adulteration has taken place or not
during transportation. Following
test are performed for raw milk:
Titratable acidity
Clot on boiling test
Alcohol test
Methylene Blue Reduction Test
Fat
SNF
Quality Testing parameters
Quality Testing parameters
Quality Testing parameters
Quality Testing parameters

Jagdamba Laboratory
Quality Testing parameters
Safety Parameters for
Contaminants

It is provided under the conditions of license as per FSSR licensing and

registration regulations that every FBO shall ensure that his food product is
tested for relevant chemical and microbiological contaminants through
FSSAI notified / NABL accredited or own laboratory at least once in six
months.
Safety Parameters for
Contaminants
Exercise

What is the role of robust milk and milk product testing in a dairy plant ?
Discuss
How could one validate that the results coming out from laboratory are
correct ? Share how does the results in your laboratory were challenged by
a third party. Experience sharing
Too much of quality testing leads to poor efficiency in a dairy plant ? Group
exercise with real time experience sharing
Quality and Process are two mutually exclusive pillars of a dairy plant ?
Debate

30-45 minutes
PART-VII
Product information & consumer
awareness
PRODUCT INFORMATION &
CONSUMER AWARENESS

Labelling
Manner of Declaration
Specific Requirements/ Restrictions on manner of labelling
Exemptions from labelling requirements
Notice of addition, admixture or deficiency in food
PRODUCT INFORMATION &
CONSUMER AWARENESS
Labeling of Pre-packaged Foods

In addition to the General Labeling requirements, every package of food

shall carry the following information on the label, namely –
Name of the food
List of ingredients in descending order
Nutritional information
Declaration regarding food additives Advance food safety
handbook/manual for food manufacturer’s, processor’s & Packers 2, 2017
Labeling of Pre-packaged Foods contd./-
Name and complete address of manufacturer or packer
Net content by weight or volume
Date of Manufacture / Packing
Lot / Code / Batch identification
Best Before Date
Instructions for use
Importer details and Country of origin for imported products
All the contents provided on the label must be clear, prominent, indelible
and legible.
Labeling of Pre-packaged Foods
contd./-
License number shall be displayed on the principal display
panel in the following format
Declaration regarding veg or non-veg

Fluid milk: — The caps of the milk bottles /pouch/tetra-pack

shall clearly indicate the nature of the milk contained in them.
The indication may be either in full or by abbreviation shown
below:
(i) Buffalo milk may be denoted by the letter ‘B’.
(ii) Cow milk may be denoted by the letter ‘C’
(iii) Goat milk may be denoted by the letter ‘G’
(iv) Standardized milk may be denoted by the letter ‘S’
(v) Toned milk may be denoted by the letter ‘T’
(vi) Double toned milk may be denoted by the letter ‘DT’
(vii) Skimmed milk may be denoted by the letter ‘K’
(viii) Pasteurised milk may be denoted by the letter ‘P; followed
by the class of milk. For example
Pasteurised Buffalo milk shall bear the letters ‘PB ‘.
Exemptions from labelling
requirements

 list of ingredients, Lot Number or Batch Number or Code Number, nutritional information and
instructions for use if package is not more than 100 cm2 but these information shall be given
on the wholesale packages or multi piece packages.
 The 'date of manufacture' or 'best before date' or 'expiry date‘ if less than 30 cm2 but these
information shall be given on the wholesale packages or multispecies packages.
 In case of liquid products marketed in bottles, if such bottle is intended to be reused for
refilling, the requirement of list of ingredients shall be exempted, but the nutritional
information specified in regulation.
 Provided that in case of such glass bottles manufactured after March 19, 2009, the list of
ingredients and nutritional information shall be given on the bottle.
 In case of food with shelf-life of not more than seven days, the 'date of manufacture' may not
be required to be mentioned on the label of packaged food articles, but the 'use by date' shall
be mentioned on the label by the manufacturer or packer.
 In case of wholesale packages the particulars regarding list of ingredients. Date of
manufacture/ packing, best before, expiry date labelling of irradiated food and, vegetarian
logo/non vegetarian logo, may not be specified.
Exercise

Whose responsibility is to provide information given on label in your dairy

plant ?
Has the information provided been validated on contents or nutritional facts
?
What is the importance of metrology in labeling ?
How often the changing labeling requirements from the regulator are
discussed in your plant ?
Share your experience on some market complain over the labeling issue
on your product and how was it resolved ?

General discussions 20-30 mts

PART-VIII
Food safety management system plan
FOOD SAFETY MANAGEMENT
SYSTEM PLAN

Introduction
Structure of the FSMS Program
Flow chart
FSMS Plan
Conclusion
Introduction of FSMS
A Food Safety Management System (FSMS) is a network of interrelated elements
that combine to ensure that food does not cause adverse human health effects.
These elements include programs, plans, policies, procedures, practices, processes,
goals, objectives, methods, controls, roles, responsibilities, relationships, documents,
records, and resources. The purpose of FSMS is to ensure the manufacture, storage,
distribution and sale of safe food.
However, under current Indian regulation defined by the FSS Act 2006, Food Safety
Management System (FSMS) means the adoption Good Manufacturing Practices,
Good Hygienic Practices, Hazard Analysis and Critical Control Point and such other
practices as may be specified by regulation, for the food business.
The Key elements of any FSMS are
Good Practices/ PRPs
Hazard Analysis /HACCP
Management Element / System
Statutory and regulatory requirements
Communication
FSMS Documentation
Structure of the FSMS
Program

Jagdamba Laboratory
Sample Flow chart for
pasteurized milk
Sample FSMS Plan for Raw milk
reception
Exercise

Develop an FSMS plan for a 200000 lpd composite dairy plant processing
pasteurized milk, Fermented milk products like Curd, butter milk, Lassi,
Panir, Sweetened flavored milk, butter and ghee ? Take any assumption on
product mix variant . Group exercise followed by presentation

The presentation must cover all key elements related to FSMS with
indicative responsibility.
How will you make food handlers about this plan in your plant

60-90 minutes
PART-IX
HACCP (Hazard Analysis and Critical
Control Point)
HACCP (Hazard Analysis and
Critical Control Point)

Introduction
HACCP Principles
Purpose & Importance of Hazard Analysis
Hazard Analysis Process, Hazard Identification& Evaluation, Control
Measures
Flow Diagram of Liquid Milk & UHT Milk processing
HACCP (Hazard Analysis and
Critical Control Point)
Introduction
Milk is highly perishable commodity and a nutritious food so there is high risk of hazard or
food poisoning. Hazard analysis is the process used by the HACCP team to determine which
potential hazards present a significant health risk to consumers. Only those hazards that
pose significant risk to the health of consumers should be included in the HACCP plan.
HACCP Principles
PRINCIPLE 1: Conduct a hazard analysis.
PRINCIPLE 2: Determine Critical Control Points (CCP)
PRINCIPLE 3: Establish critical limit (s).
PRINCIPLE 4: Establish a system to monitor control of the CCP.
PRINCIPLE 5: Establish corrective action to be taken when monitoring indicates that a
particular CCP is not under control.
PRINCIPLE 6: Establish procedures for verification to Confirm that HACCP system is
working effectively.
PRINCIPLE 7: Establish documentation concerning all procedures& records appropriate
to these principles and their application
HACCP (Hazard Analysis and
Critical Control Point)
Purpose of the Hazard Analysis
The purpose of the hazard analysis is to develop a list of hazards which are of such
significance that they are reasonably likely to cause injury or illness if not effectively
controlled.
Successful application of HACCP principles 2-7 depends on a high-quality hazard
analysis
Importance of Conducting a Thorough Hazard Analysis
An improper hazard analysis may result in a HACCP plan that is not effective in
protecting consumers regardless of how well it is followed.
Plant operations may be modified based on a thorough hazard analysis.
Hazard Analysis Process
Hazard Identification and Determination of Acceptable Levels
List of potential hazards that may be associated with a milk and milk product.
Determination of the acceptable level for each identified food safety hazard.
HACCP (Hazard Analysis and
Critical Control Point)

Hazard Identification
HACCP team develops a list of potential biological, chemical, and physical hazards
that may be introduced, increased, or controlled at each step described on the
product flow diagram.
The preliminary information collected while developing the product description
Experience
External information including, when possible, epidemiological and other historical
data
Information from the food chain on food safety hazards that may be of relevance
for the safety of the end products, intermediate products and the food at
consumption
HACCP (Hazard Analysis and
Critical Control Point)

Determination of Acceptable Levels

For each food safety hazard identified, its acceptable level in the end
product shall be determined whenever possible.
This determination shall consider:
Regulatory requirements
Customer requirements
Intended use by the customer
Other relevant data
Record the result of the determination and its justification.
HACCP (Hazard Analysis and
Critical Control Point)

Hazard Evaluation
Evaluation based on the likelihood of occurrence and the severity of effects
of a particular hazard.
Identify which of the potential hazards pose a significant risk to the
consumer.
The HACCP team decides which of the potential hazards listed during
hazard identification stage present a significant risk to consumers.
Each potential hazard should be evaluated based on two factors:
Severity (of the potential illness or injury)
Likelihood of occurrence
HACCP (Hazard Analysis and
Critical Control Point)

Evaluating Severity
Will require consideration of various factors, including:
Susceptibility of intended customers to foodborne illness (e.g. children
versus adults)
Possible impact of secondary problems
Magnitude and duration of the illness or injury
Estimating Likelihood of Occurrence
Experience
Data from past foodborne illness outbreaks
Information in the scientific literature
Historical information gathered by the establishment
HACCP (Hazard Analysis and
Critical Control Point)

Factors Influencing Likelihood of Occurrence

Effectiveness of prerequisite programs
Frequency of association of the potential hazard with the food or ingredient
Method of preparation
Conditions during transportation
Expected storage conditions
Likely preparation steps before consumption
HACCP (Hazard Analysis and
Critical Control Point)
Control Measures
Any action or activity that can be used to prevent or eliminate a food safety hazard, or reduce
it to an acceptable level.
Often termed “Preventive Measures” in earlier HACCP documents.
More than one control measure may be required for a specific hazard.
More than one hazard may be addressed by a specific control measure.
Examples of Control Measures
Filtration
Pasteurization
Thermal processing
Acidification
Fermentation
Disinfection
Refrigeration
Freezing
Metal detectors
X-ray devices
Irradiation
Exercise

How does you identify CP, CCP and SOP at your dairy Plant ? Group
exercise by taking an example of a process section each for a group.
How would you make your food handler understand the importance of CP,
CCP and SOP? 3-4 brief experience sharing
Too much of SOP at plant kills productivity ?Debate

60-90 minutes
PART- X
Pest Control
Pest Control
Garbage lying
open – Source
of flies, insects,
rodents

Open &
unattended
garbage bins
Pest Control Methods
Pest control Method Continue
Pest control Method Continue
Exercise

Share the pest issues at your plant and how have you resolved them ?
Share the emerging trends in pest control at your plant ?
How does plant designing help in pest control at a dairy plant ?

20-30 minutes