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HACCP MANUAL
Githunguri Dairy Farmers Co-Operative Society ltd (GDFCS) is committed to providing safe dairy
products to our consumers by ensuring that all stages of milk production, collection, processing,
storage and distribution conform to the highest food safety standards.
GDFCS shall establish and maintain appropriate programmes to ensure customer satisfaction First
Time All Times.
We shall endeavor to monitor and review the established food safety management system to
continuously conform to the requirements of ISO 22000:2005 standard.
Definitions
Food safety
Concept that food will not cause harm to consumers when prepared /eaten according to intended use.
Food chain
Sequence of the stages and operations involved in the production, processing, distribution, storage
and handling of a food from primary production to consumption.
End Product
Product that will not undergo any other processing/transformation by the organization.
Control Measure
Action or activities that can be used to prevent or eliminate a food safety hazard.
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GITHUNGURI DAIRY FARMERS CO-OPERATIVE SOCIETY LTD MILK PLANT
Hazard analysis.
Systematic identification of hazards, assessment of risk associated with the hazards, establishment of
control measures and critical control points within a segment of food chain.
Correction
Action to eliminate a detected non conformity.
Corrective action
Action to eliminate the cause of a detected non conformity.
Verification.
Confirming through the provision of objective evidence that specified requirements have been meet.
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Validation
Obtaining evidence that the control measure are capable of being effective
HACCP plan
A document prepared in accordance to HACCP principle and aimed at ensuring the control of hazard
in the segment of the food chain under consideration.
5. Establish the corrective action to take when monitoring indicates that a particular CCP not in
control.
6. Establish procedures for verification to confirm that the HACCP system is working effectively.
7. Establish documentation concerning all procedures and records appropriate to these principles
and the application.
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GITHUNGURI DAIRY FARMERS CO-OPERATIVE SOCIETY LTD MILK PLANT
5.
7.
8
Establish monitoring system for each CCP
9.
Physical hazards
Chemical hazards
Biological Hazards
1. Physical hazards/contaminants.
These are mainly associated with foreign matter. The foreign matter be may come with raw materials, packaging
materials, water be introduced during production from the environment or from food handlers.
2. Chemical hazards/Contaminants.
These are introduced through raw material, water, surface contact, handling or added during preparations.
Chemical hazard cause long term health effect since they accumulate in the host body.
3. Biological Hazards.
These are micro organism capable of causing illness when ingested with food. They are introduced in food
from raw materials, dirty equipments/packaging materials, pests, food handlers, waste and dust and aerial
contaminants. These pathogens fall into 3 categories.
Score < 5 Preventative control measures, but do not enter decision tree
QUESTION 1 (Q1): Do preventive control measures prevent, eliminate or reduce the hazard to an acceptable
level?
ANSWER: If Yes proceed to Q2, if No modify process (and make a new rating) or develop new preventative
control measure that does prevent, eliminate or reduce the hazard to an acceptable level.
QUESTION 3 (Q3): Will a subsequent process step eliminate or reduce hazard to an acceptable level?
ANSWER: If No proceed to Q4, if Yes NOT CRITICAL, SO PRE-REQUISITE PROGRAMME
QUESTION 4 (Q4): Can the hazard be monitored by objective, direct measurable parameters for controlling
all the products?
ANSWER: If Yes CCP (CRITICAL CONTROL POINT), if No O-PRP (EXTRA IMPORTANT GENERAL
MEASURE IN PRE-REQUISITE PROGRAMME)
Biological - nil
- hand gloves/nurse
caps
-
- glass fragments
- cleaning
- material/fibers
Biological - Nil
6 Packaging Chemical detergent residue 13 = 3 - - - - PRP - Cleaning and
- sanitizing agent 11 = 1 - - - - Sanitation program
- lubricants 10.5 = 0.5 - - - - - Preventive
Maintenance
GHEE PROCESSING
OPRP PLAN
PROCESS HAZARD LIMIT CONTROL MONITORI CORRECTI CORRECTIVE RESPONSI VERIFICA RECORD
MEASURE NG ON ACTION BILITY TION
1 Grading Antibiotic Nil Training of Antibiotic Isolate/evaluat -Communicate Lab QAS RM QC 1
s milk Test per batch e/reject & retrain Assistant
suppliers. /Test per can
2 Preservati <2 ppm Training of H202 Test per Isolate/evaluat -Communicate Lab QAS -RM QC 1
ve (H202) milk sampling plan e/reject & retrain Assistant -H202
suppliers sampling
plan
3 Filtrations Pathogens <1000 - Cleaning Start of every Reclean/evalu -Communicate Operator Production -Inline
(B.arbotus CFU and milk ate & Training Supervisor filters
, E.coli, L. Sanitation in reception(2 -Adhere to records
monocyto line filters hrs stoppage) Cleaning and (OPRP-
genes, Y. Sanitation FORM-
enterocolit program 01)
ica,
C.jejuni,
S.typhimu
rium,M.tu
berculosis
)
4 Past milk Pathogens <10 - Cleaning -Adhere to Isolate/evaluat -Communicate Operator Production PM QC 2.
storage (B.arbotus CFU and Cleaning and e/reject/Repro & Training Supervisor -Tank
, E.coli, L. Sanitation Sanitation cess -Adhere to Seals
monocyto program schedule Cleaning and record
genes, Y. -Securing -Check seals Sanitation (OPRP-
enterocolit tanks program FORM-
ica, 02)
C.jejuni,
S.typhimu -C.I.P
rium,M.tu records
26 Butter Pathogens <10 -Aseptic - Adhere to Isolate/evaluat -Communicate Production -Production Processing
CCP PLAN
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PROCESS HAZARD CRITICAL CONTROL MONITOR CORRECT CORRECTIVE RESPONSI VERIFICA RECORD
LIMIT MEASURE ING ION ACTION BILITY TION
1 Raw milk Pathogen Temperature Attainment Accurate Isolate and -Proper -Operator -Production -PHE Past
pasteurizati (B.arbotus >720C Time of Past temp Temp reprocess maintenance of Supervisor log sheet
on , E.coli, L. >15 sec and holding readings flow diversion (CCP-
monocyto time every 30 valve. -Plant FORM
genes, Y. min. -Calibration of Maintenanc 01)
enterocolit gauges e Engineer QAM Preventive
ica, Maintenan
C.jejuni, ce record/
S.typhimu Calibratio
rium,M.tu n records
berculosis
)
2 Yoghurt Pathogens Temperature Attainment Accurate Isolate and -Proper -High value -Production -Batch
milk heat (B.arbotus >850C of heating readings reprocess maintenance of Production Supervisor past log
treatment , E.coli, L. Time >30 temperature from temperature Assistant sheet(CCP
monocyto min and holding temperature gauges -FORM
genes, Y. time gauges and -Calibration of -Plant 02)
enterocolit timer every gauges Maintenanc QAM Preventive
ica, 15 min on e Engineer Maintenan
C.jejuni, attaining ce record/
S.typhimu 850C Calibratio
rium,M.tu n records
berculosis
)
3 Cream Pathogens Temperature Attainment Accurate Isolate/eval -Proper -High value -Production -Batch
pasteurizati (B.arbotus >850C Time of Past temp readings uate and maintenance of Production Supervisor past log
on ,E.faecium >30 min and holding from reprocess temperature Assistant sheet(CCP
,E. time temperature gauges -FORM
faecalis) gauges and -Calibration of -Plant 03)
timer every gauges Maintenanc QAM Preventive
15 min on e Engineer Maintenan
4 Ghee butter Pathogens Temperature Attainment Accurate Isolate and -Proper -High value -Production -Ghee pot
heat (L.monoc >1100C of heating hourly reprocess maintenance of Production Supervisor log
treatment ytogenes, temperature readings temperature Assistant sheet(CCP
S.aureus,C from gauges -FORM
.jejuni,H.p temperature -Calibration of -Plant 04)
ylori,C.dif gauges gauges Maintenanc QAM Preventive
ficile,S.py e Engineer Maintenan
ogenes,M. ce record/
tuberculos Calibratio
is) n records