HACCP Study Joghurt

Document No: COM-HACCP-001 Issue No: 7
Issue Date: 2/4/2010 Issued By: ED

Reason for amendment: General Update Authorised By: CM
Page No: 1 of 13
Site:
The HACCP study covers the manufacture and packing of stirred yogurt types from milk intake, raw milk storage, yogurt base blending, standardisation, homogenisation ,
Scope
heat treatment, cooling, inoculation of tanks, incubation, potting of yogurt, cooling, storage and distribution to customers for end use by consumers.
Product: Stirred Yogurt, including Biolive and Probiotic yogurts

Composition: Raw Cow's milk
Structure: Homogenous blend of dairy ingredients and ingredients and flavourings in liquid form
Processing Blending, standardisation, homogenisation, heat treatment,cooling and innoculation with bacterial dairy starter, incubationmixing of ingredients, potting and cooling.
Packaging: Polystyrene pots multipack format, rPet Single pot format, Polystyrene Single Pots, Polypropylene single pots. PET lids or Foil lids. Polypropylene or rPet Overcaps
Storage / Distribution Chilled below 5°C, target 1 - 5°C maximum 5°C
Required Shelf Life: To XXXX specification of target 23/25 or 27 days, minimum 16 days into depot.
Instructions for Use: Keep refrigerated 1 - 5°C or see Customer specification details. Use within three days of opening - retail packs only.
Intended Use by Consumer: All population, without further processing excluding children of certain age groups. - See below.
Food Safety Act 1990 and all subsequent legislative documents and amendments there under. Codex alimentarius, Allergen Legislation 2003 /89EC Amendment Directive
Legislation: 2000 /13EC. Animal By Products Regulations 2005, Food Labelling regulations 2004, Food Hygiene) Wales regulations 2006, Yogurt Code of Practice.  Plastic Materials
and Articles in Contact with Food Regulations 1998 (as amended)
Related Documents FSQ-002 Management of Food Safety and HACCP; FSQ-002 APP1 Pre Requisite Programme
Micro/chemical criteria See XXXX Laboratory Work Instructions
Hazards identified The hazards that the study will be used to identify include Microbiological (M), Physical (P) Chemical (C) and Allergenic (A)
Allergen Advice Contains Milk -
Health Guidance to Consumers: Not suitable for babies under 4 months old
HACCP TEAM MEMBER JOB FUNCTION HACCP RESPONSIBILITY TRAINING

Carolyn Mills (Team Leader) Quality Control Manager Team Leader RIPHH HACCP Principles - Int
Richard Cooper Operations Manager Production RIPHH HACCP Principles - Int
Jo Tett-Davies Technical Manager Technical RIPHH HACCP Principles - Int
Mark Williams Senior Engineer Engineering RIPHH HACCP Principles - Int
Trevor Stables Senior Engineer Engineering RIPHH HACCP Principles - Int
Elin Davies Quality Development Officer Technical RIPHH HACCP Principles - Int
Ben Kinsey NPD Technologist Technical RIPHH HACCP Principles - Int
Katie Lea Innovations Manager NPD RIPHH HACCP Principles - Int
Lesley Daniel Production Planner Planning RIPHH HACCP Principles - Int
Verified By Date Verified

Page No: 2 of 13
REASON FOR HACCP STUDY: * Completion Date Completed By Comments
NS 11/21/2008 C Mills New Study to bring into line with changes to BRC Version 5
UR 12/28/2008 C Mills Addition of Lesley Daniel to HACCP Team

SR 6/29/2009 C Mills Scheduled Review of HACCP
UR 10/12/2009 C Mills Change pot format to PP, PS, rPet etc
UR 12/18/2009 C Mills Plastic Materials and Articles in Contact with Food Regulations 1998 (as amended)
UR 12/28/2009 C Mills Add Allergenic as stand alone
UR 2/4/2010 C Mills Review of Distribution Temperatures
*Note: New Study (NS) / Scheduled Review (SR) / Unscheduled Review (UR)
Page No: 3 of 13
HACCP Flow Diagram for Stirred Yogurt
1. Raw Milk & Ingredient Purchasing

2. Raw Milk Reception CCP1
3. Raw Milk Storage
4. Preheating & Separation of some

Raw Milk into Skim Milk & Cream
6. Reconstitution of SMP with 5. Thermisation and Cooling of Skim

Cream
Thermised Skim Milk Milk
7. Blending of Raw Milk with Skim

Milk/SMP/WPC/SMC/Cream/Sugar as
applicable.
8. Heating & Homogenisation
9. Thermal Treatment CCP2
10. Cooling and transfer to Inoculation

Tanks
11. Inoculation of Yogurt Base
12. Incubation of Yogurt Base CCP3
14. Pumping and Mixing of Yogurt

Base & Ingredients
Waste Disposed of via Category Note and

Recovered Bulk
Approved Waste Carrier. No Rework.
15. Pot Filling, Sealing & Coding
16. Blast Chilling
17. Sleeving of Multipacks/Addition of

Top Hat Overlids
18. Metal Detection CCP4
19. Cold Storage & Despatch

Reason for amendment: General Update Authorised By CM
Page No: 4 of 13
Risk Analysis
To assess the likely occurrence of hazards and the severity of their adverse health effects, XXXX Dairy require the following quantitive evaluation of the presence of hazards to be carried out based on management knowledge and
experience, using hisotical data also where available.
Definition of Risk: An estimate of the LIKELIHOOD of the hazard occuring and its IMPACT on health.
RISK = IMPACT x LIKELIHOOD
e.g. probability of hazard occuring.
Assessment
This assessment shall be carried out using the following scores;
For the likelihood of a hazard occuring, allocate a figure from the horizontal axis on the chart above, and record the reason.
Assess how severe the impact would be on food safety / customer health by allocating a value from the vertical axis, and record the reason.
Record the risk by multiplying the score.
Likelihood
Risk Assessment 3 2 1
Probable. Occasional Improbable
3. Critical 9 6 3
Impact
2. Serious 6 4 2
1. Negligible 3 2 1
Red Food Safety Risk if not controlled. Priority should be given to addressing these issues.
Yellow Potential for Food Safety Risk if not controlled.
Green
Low food safety issue but relevant controls amy still be needed to comply with quality, legal or customer issues.
Reason for amendment: General Update Authorised By CM
Page No: 5 of 13
Process Step Hazards

No Description Type Source Likelihood Impact Risk Risk Justification
Occurrence improbable based on historical complaint data. Consideration given to raw milk that may be adulterated or
1A P Foreign matter 1 2 2
maliciously contaminated occurrence is improbable based on historic data.
Supplier approval and
receipt. All Milk is sourced Multiplication of pathogens and
1B from XXXX Cooperative. M spoilage organisms possible heat 3 3 9 Probable in milk, and if not controlled, a food safety hazard.
Sugar, Whey Protein stable toxin production.
Concentrate, Cream and
Skim Milk Powder are all
sourced from approved Occurrence occasional in milk, mainly due to antibiotics/feed/chemical taints, severity is minimal due to controls at
suppliers. Residues and chemical farm, however antibiotic residue could be critical in the long term. Packaging bought against specification and checked
1C C 1 3 3
contamination visually for damage on receipt, historical complaint information does not identify problems. Organic Status of milk is
confirmed prior to unloading.
Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen advice on consumer
1D A Allergenic Material 3 3 9
packaging
Occurrence improbable, possible contaminants could be due to defective tanker equipment or detergent residues e.g.
2A P Foreign matter 1 2 2 scale. Adulteration or malicious contamination occurrence improbable based on historic data. Milk is filtered through a
1 mm filter
Multiplication of pathogens and

2B Raw milk inspection and off M spoilage organisms possible heat 3 3 9 Probable in milk, and if not controlled, a food safety hazard. Unlikely in packaging.
loading into Raw Milk Silo stable toxin production.
X2 , Silo capacity 120,000
litres total Chemical contamination
Occasional antibiotic/feed/chemical taint, severity is minimal due to controls at farm, however antibiotic residue could
2C C including antibiotics harmful to 1 3 3
affect the fermentation process and would not conform to Organic Standards
health
packaging
Occurrence improbable, possible contaminants could be due to defective equipment or detergent residues e.g. scale.
Adulteration or malicious contamination improbable based on historic data.

Probable in raw milk only, and if not controlled, a food safety hazard. Stored for 48 hours maximum. Can be used under
3B M spoilage organisms possible heat 3 3 9
Raw milk storage concession beyond this point.
stable toxin production.
Residues and chemical Historical data indicates limited likelihood of occurrence when tanker testing controls in place, with minimal risk from
3C C 1 2 2
contamination cleaning chemicals. Final fresh water rinse.
packaging
Occurrence improbable, possible contaminants could be due to defective equipment or scale/burnt on milk. Adulteration
or malicious contamination improbable based on historic data.
Processing (including pre Multiplication of pathogens and

4B heating, separation, skim M spoilage organisms possible heat 3 3 9 Probable in milk, and if not controlled, a food safety hazard
undergoes Thermisation and stable toxin production.
cooling, cream undergoes
pasteurisation, and cooling ) Residues and chemical Historical data indicates limited likelihood of occurrence, with minimal risk from cleaning chemicals. Final fresh water
4C C 1 2 2
contamination rinse.
packaging
Occurrence improbable, possible contaminants could be due to defective equipment or scale residues. Adulteration or
malicious contamination improbable based on historic data.

Storage of thermised cooled Skim thermised, cooled and stored in insulated tanks. Target storage time less than 24 hours. Concession required for
skim storage time beyond this with a maximum of 60 hours. Product to be fully pasteurised if extended storage time required.
Residues and chemical Historical data indicates limited likelihood of occurrence, with minimal risk from cleaning chemicals. Final fresh water
5C C 1 2 2
packaging
Page No: 6 of 13

Occurrence improbable, possible contaminants could be due to defective equipment, scale residues or from Skim Milk
Powder packaging. Adulteration or malicious contamination improbable based on historic data.

Product reconstituted using thermised skimmed milk and stored in insulated silo. Target storage time less than 24 hours.
Reconstitution of Skim Milk Concession required for storage time beyond this with a maximum of 60 hours.
Powder
6C C 1 2 2
packaging
Occurrence improbable, possible contaminants could be due to defective equipment or Ingredients. Ingredients
7A P Foreign matter 1 1 1 purchased via an approved supplier. Equipment is on Preventative and Planned maintenance system. Adulteration or
Blending Operation malicious contamination improbable based on historic data.
(includes blending of Raw
Milk / Skimmed Milk/
Cream reconstituted Skim Multiplication of pathogens and
Milk Powder/ Whey Protein Blended product to be used within a target time of 24 hours, with a maximum time of 48 hours. Pasteurised from these
Concentrate/Skim Milk tanks.
Concentrate/ organic sugar
as applicable) to desired fat Residues and chemical Historical data indicates limited likelihood of occurrence, with minimal risk from cleaning chemicals. Final fresh water
7C and protein level. C 1 2 2
packaging

8B Heating and M spoilage organisms possible heat 3 3 9 Probable in milk, and if not controlled, a food safety hazard
Homogenisation stable toxin production.
8C C 1 2 2
packaging
Survival & multiplication of
pathogens and spoilage
9B Thermal Treatment of M 1 2 2 Survival & multiplication of pathogens and spoilage organisms with possible heat stable toxin production.
organisms possible heat stable
Yogurt Base toxin production.
9C C 1 2 2
packaging
Occurrence improbable, possible contaminants could be due to defective equipment or scale residues. Adulteration or
malicious contamination improbable based on historic data. Inline filtration

Cooling to incubation
10B M spoilage organisms possible heat 1 1 1 Product heat treated and stored in insulated tanks. Therefore is not a food safety risk.
temperature. (Transfer to
inoculation Tanks)
10C C 1 2 2
10 D A Allergenic Material 3 3 9
packaging
Occurrence improbable, possible contaminants could be due to defective equipment or scale residues or starter
packaging

Cleaning routines vary from fully automated to manual, controlled via Prerequisites. Possibility of product spoilage if
Inoculation of Yogurt Base not carried out effectively.
with Dairy Starter Culture.
11C C 1 2 2
packaging
Page No: 7 of 13

Occurrence improbable, possible contaminants could be due to opening lid to take sample for pH testing. Enclosed
system

Incubation of Yogurt Base Slow Vat procedure in place. Must reach a pH of 4.6 in a maximum of 15hours and Starter Rotation as required.
Potential Phage contamination controlled by fogging schedule.
Residues and chemical Historical data indicates limited likelihood of occurrence, with minimal risk from cleaning chemicals.
12C C 1 2 2
contamination Final fresh water rinse.
packaging
Occurrence improbable, possible contaminants could be due to defective equipment or scale residues. Ingredients
bought in from approved suppliers. Filtration in Place
Pumping And Mixing Multiplication of pathogens and

(ingredients and flavours as Cleaning routines vary from fully automated to manual, controlled via Prerequisites. Possibility of product spoilage if
applicable) not carried out effectively.
Residues and chemical Historical data indicates limited likelihood of occurrence, with minimal risk from cleaning chemicals. Final Fresh Water
13C C 1 2 2
packaging
Foreign matter Occurrence occasional but with minimal impact, mainly packaging. Adulteration and malicious contamination
14A P 1 2 2
improbable based on historic data.
Pot Filling, Sealing and Multiplication of pathogens and Cleaning routines include CIP and are controlled via pre-requisites.
14B Coding M spoilage organisms possible heat 1 1 1 Filler intervention historically does not indicate major contamination problems but could be responsible for spoilage
stable toxin production. issues.
Residues and chemical Historical data indicates limited likelihood of occurrence, with minimal risk from cleaning chemicals. Final Fresh Water
14C C 1 2 2
packaging
Foreign matter
15A P 1 2 2 Only sealed packs handled, any damaged packs removed.

Sealed packs subjected to temperature abuse could ferment / spoil, but not a safety issue, controlled to maintain shelf
15B Blast Chilling M spoilage organisms possible heat 1 1 1
life. .
Residues and chemical

15C C 1 2 2 Limited risk from environmental cleaning as packs are sealed. All damaged packs removed.
contamination
packaging
16A P Foreign matter 1 1 1 Occurrence occasional, mainly packaging.

16B M spoilage organisms possible heat 1 1 1 Minor risk as product processed but possible spoilage risk affecting shelf life quality.
Sleeving of Multipack / Top stable toxin production.
Hat Overlids
16C C 1 1 1 Historical data indicates limited likelihood of occurrence, with minimal risk from cleaning chemicals
contamination
packaging
17A P Foreign matter 1 1 1 Occurrence improbable, possible contaminants could be due to defective equipment or scale residues.

Cleaning routines vary from fully automated to manual, controlled via Prerequisites. Possibility of product spoilage if
not carried out effectively.
Metal Detection
17C C 1 1 1 Historical data indicates limited likelihood of occurrence, with minimal risk from cleaning chemicals
contamination
packaging
Page No: 8 of 13

18A P Foreign matter 1 1 1 Only sealed packs handled, any damaged packs removed.

Sealed packs subjected to temperature abuse could spoil/ferment, but not a safety issue, controlled to maintain shelf
life. .
Cold Storage and dispatch
18C C 1 1 1 Limited risk from environmental cleaning as packs are sealed. All damaged packs removed.
contamination
packaging

Page No: 9 of 13
HACCP DECISION TREE

(Based on Codex Alimentarius)
Answer each question in sequence at each process step for each identified hazard
Q1. Do control measures exist?
Modify step, process or product
YES NO
YES
Q1a. Is control necessary at this step for safety?
NO
Stop*
Q2. Is the step specifically designed to eliminate or reduce the likely

occurrence of a hazard to an acceptable level?
YES
NO
Q3.Could contamination with identified hazard(s) occur in excess of

acceptable level(s) or increase to unacceptable level(s)?
NO
YES
Stop*
Q4.Will a subsequent step eliminate the identified hazard(s) or reduce their

likely occurrence to an acceptable level?
NO
YES
CRITICAL CONTROL
Stop* POINT
* Stop and proceed with the next identified hazard(s)

Issue Date 2/4/2010 Issued By: ED
Page No: 10 of 13
HACCP Study for Stirred Yogurt NRC: Decision Tree
Process Step Hazards Decision Tree

Control Measures Is it a CCP? CCP No
No Description Type Source Risk Q1 Q2 Q3 Q4
1A P Foreign matter 2 Visually inspect prior to / at offloading. Purchased to Approved Supplier Specification. Y N N N
Multiplication of pathogens and spoilage organisms possible

1B M 9 Purchased against Approved Supplier Specification Y N Y Y N
heat stable toxin production.
Supplier approval and receipt. All Milk is
sourced from XXXX Cooperative Purchased against Approved Supplier Specification.
1C C Residues and chemical contamination 3 Y N N N
Supplier Monitoring
Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen
1D A Allergenic Material 9 Y N N N
advice on consumer packaging
Organic Status checked. Visually inspect prior to offloading. Tanker is rejected if milk is outside
2A Foreign matter 2 Y N N N
specification. Filtered on offloading from tanker.

2B M 9 Tanker is rejected if milk is outside specification. Y N Y Y N
Raw milk inspection and off loading into
Raw Milk Silo X2 , Silo capacity 120,000 Sampling and testing of incoming raw milk supplies to detect antibiotics. Tanker is rejected if milk is
2C litres total C Chemical contamination including antibiotics harmful to health 3 Y Y Y 1
outside specification.
3A P Foreign matter 2 Filters in CIP system, enclosed covered equipment Y N N N

3B M 9 Correct rotation of silos / temperature control. Routine testing of raw milk Y N Y Y N
Raw milk storage heat stable toxin production.
3C C Residues and chemical contamination 2 Cleaning systems checked and verified. Y N N N

4A P Foreign matter 1 Enclosed and covered equipment filtered/separated prior to heat treatment. Personal hygiene rules Y N N N
Multiplication of pathogens and spoilage organisms possible Heat treated at further stage as per legal and site requirements. Equipment validated minimum
4B M 9 Y N Y Y N
heat stable toxin production. annually.
Processing (including pre heating,

separation, skim Thermisation and
4C cooling of product ) C Residues and chemical contamination 2 Cleaning systems checked and verified. Y N N N
5A P Foreign matter 1 Enclosed and covered equipment filtered/separated prior to heat treatment. Personal hygiene rules Y N N N

5B M 9 Stock Rotation Y N Y Y N
Storage of thermised product (skim) heat stable toxin production.
5C C Residues and chemical contamination 2 Cleaning systems checked and verified. Y N N N
Occurrence improbable, possible contaminants could be due to defective equipment or scale

6A P Foreign matter 3 Y N N N
residues. Adulteration or malicious contamination improbable based on historic data.
Multiplication of pathogens and spoilage organisms possible Product reconstituted using thermised skimmed milk and stored in insulated silo. Target storage time
6B M 9 Y N Y Y N
heat stable toxin production. less than 24 hours. Concession required for storage time beyond this with a maximum of 60 hours.
Reconstitution of SMP
Historical data indicates limited likelihood of occurrence, with minimal risk from cleaning chemicals.
6C C Residues and chemical contamination 2 Y N N N
Final fresh water rinse.
7A P Foreign matter 1 Enclosed equipment and packaging. Personal hygiene rules. Y N N N
Scheduled cleaning and equipment.

7B M 9 Monitoring of environment and personnel. Y N Y Y N
Intervention procedure for manual handling of equipment.
Blending Operation
7C C Residues and chemical contamination 2 Validation of procedures annually. Monitoring of post cleaning hygiene checks Y N N N
Page No: 11 of 13

8A P Foreign matter 1 Visual inspection. Y N N N

8B M 9 Yogurt Base rejected if fails to meet specification, including temperature and stock rotation. Y N Y Y N
Heating and Homogenisation

8C C Residues and chemical contamination 2 Cleaning controlled. Validation of equipment and procedures annually. Y N N N
9A P Foreign matter 2 Enclosed and filtered CIP Systems. Y N N N

9B M 1 Product Divert. Monitoring of Hygiene and Detergent concentrations Y Y Y 2
9C C Residues and chemical contamination 2 Scheduled cleaning of equipment. Assured CIP cleaning methods. Verification of equipment. Y N N N
Thermal Treatment of Yogurt Base
10A P Foreign matter 1 Enclosed system Y N N N
Multiplication of pathogens and spoilage organisms possible Chilled storage / distribution maintained to ensure shelf life requirements met. Prerequisite standards
10B M 1 Y N N N
heat stable toxin production. apply.
Cooling to incubation temperature.

(Transfer to Inoculation Tanks)
10C C Residues and chemical contamination 2 Scheduled cleaning of area to Prerequisite standard to prevent cross-contamination. Y N N N
Enclosed and covered equipment. Coloured pots used. Personal hygiene rules. After incubation
product is filtered at the flow plate.
11B M 9 Hygiene rules. Sterilisation of pots. Personal hygiene rules Y N N N
Inoculation of tanks
12A P Foreign matter 2 After incubation product is filtered at the flow plate to remove any potential contamination Y N N N
Multiplication of pathogens and spoilage organisms possible Correct rotation of tanks, time for pH to strike 4.4-4.6 in < 15 hours. Potential phage contamination
12B B 9 Y Y Y 3
heat stable toxin production. controlled by fogging and starter rotation as required.
Tank Incubation
Fruit preparations are purchased from an approved supplier. After adding to yogurt, hopper lids are
fitted.
Continues filling process. During breakdowns product will be potted off, quarantined until
13B M 1 Enterobacteriaceae results are obtained. For breakdowns of greater than 2 hours the hopper will be Y N N N
emptied, product disposed and the hopper cleaned.
Pumping And Mixing
Foreign matter Mixed yogurt is not filtered use to pieces of fruit in the yogurt. Metal pieces can be detected further
14A P 2 Y N N N
down the line

14B M 1 Seal checks are carried out as per schedule. Date Code, Packaging Checks and Weight Control. Y N N N
Pot Filling, Sealing and Coding

Foreign matter
15A P 2 Enclosed pots. Y N N N

15B M 1 Pots chilled to <5°C Y N N N
15C Blast Chilling C Residues and chemical contamination 2 Scheduled cleaning of area to Prerequisite standard to prevent cross-contamination. Y N N N
Page No: 12 of 13

16A P Foreign matter 1 Enclosed pots Y N N N

16B M 1 Pots removed from Blast Chiller for wrapping. Once wrapped placed in cold store Y N N N
16C Sleeving of Multipack/ Top Hat Overlids C Residues and chemical contamination 1 Scheduled cleaning of area to Prerequisite standard to prevent cross-contamination. Y N N N
17A P Foreign matter 1 Potential contamination from metal may be detected at this stage. Y Y Y 4
Multiplication of pathogens and spoilage organisms possible Pots removed from Blast Chiller for metal detection, during the wrapping operation. Once wrapped
17B M 1 Y N N N
heat stable toxin production. placed in cold store
Metal Detection
17 D A Allergenic Material 9 Y N N N
18A P Foreign matter 1 Enclosed pots Y N N N

18B M 1 Cold stored until despatch. Despatched to distribution centres in a chilled vehicle. Y N N N
18C Cold Storage and dispatch C Residues and chemical contamination 1 Scheduled cleaning of area to Prerequisite standard to prevent cross-contamination. Y N N N
18 D A Allergenic Material 9 Y N N N

Page No: 13 of 13
Process Step Control Risk / Hazard Control Critical Limits Monitoring Procedure
CCP Issue Measure
No Description Work Instruction* / Corrective
Target Tolerance Check Frequency Checked By Record Action
Chemical contamination by
Screen for
antibiotics possibly detrimental Sampling and testing Driver / Reject tanker to meet
Raw milk inspection antibiotics to Each tanker / Lab Report
2 CCP1 to consumer health. Could of incoming raw milk Absent None Operator / Lab Animal By-Product
and offloading industry test compartment QAC-GEN-014
affect Fermentation Process & supplies Staff legislation requirements.
standard
Contravenes Organic Status.
Continuous Recirculate plant until

88°C - 92°C Thermograph /
Divert at 88°C automated record / Process satisfactory conditions
(dependent on Past temp Operator's log
Pasteurised as per calibrated yearly Operative achieved / or shutdown /
equipment) PRD-GEN-042
Dairy Hygiene Regs by external agent stop production
2006 and site
standards
Survival of pathogens due to In auto, record min Shut down plant / stop
4 Thermal Treatment CCP2 Thermograph /
under pasteurisation 88°C on rising and min 88°C None Daily Past operator production. Notify
Operator's log
falling Management
Flow Rate and / or Plant Startup and

Preset holding time, If holding time is below
minimum 330 measurement of change overs/ Operator / Operator's Log/
with a target of 330 330 seconds agreed setting, stop the plant
seconds flow rate by annually by external Calibration Record
seconds and report to Management.
external verification external agent
Survival & multiplication of pH and Report to QAM

Incubation of Yogurt Time and pH strike pH 4.4-4.6 < 9 pH 4.6 / Maximum Lab Report
10 CCP3 pathogens due to Slow Temperature Every Tank Lab immediately. Stop
Base Measurement hours 15 hours QAC-GEN-031
Fermentation Checks production.
Full detection to
Metal Detector Wrapping Log /
2.5mm Ferrous, 3.0 Per pallet of Product quarantined and re-
None Checks with Test Despatch Lab Report
mm non-Ferrous and product checked.
Pieces QAC-GEN-017
Non detection of metal Test all pots through 3.5mm Stainless Steel
16 Metal Detection CCP4
contamination in product metal detector
Multipacks Full Metal Detector
Per pallet of Wrapping Log / Product quarantined and re-
detection of 3.5mm None Checks with Test Despatch
product Lab Report checked.
Ferrous Test Piece Pieces

HACCP Study Joghurt

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Document No: COM-HACCP-001 Issue No: 7

Issue Date: 2/4/2010 Issued By: ED

Product: Stirred Yogurt, including Biolive and Probiotic yogurts

HACCP TEAM MEMBER JOB FUNCTION HACCP RESPONSIBILITY TRAINING

Verified By Date Verified

REASON FOR HACCP STUDY: * Completion Date Completed By Comments

UR 12/28/2008 C Mills Addition of Lesley Daniel to HACCP Team

HACCP Flow Diagram for Stirred Yogurt

1. Raw Milk & Ingredient Purchasing

4. Preheating & Separation of some

6. Reconstitution of SMP with 5. Thermisation and Cooling of Skim

7. Blending of Raw Milk with Skim

8. Heating & Homogenisation

9. Thermal Treatment CCP2

10. Cooling and transfer to Inoculation

11. Inoculation of Yogurt Base

12. Incubation of Yogurt Base CCP3

14. Pumping and Mixing of Yogurt

Waste Disposed of via Category Note and

15. Pot Filling, Sealing & Coding

16. Blast Chilling

17. Sleeving of Multipacks/Addition of

18. Metal Detection CCP4

19. Cold Storage & Despatch

Record the risk by multiplying the score.

Process Step Hazards

Multiplication of pathogens and

Multiplication of pathogens and

Processing (including pre Multiplication of pathogens and

Multiplication of pathogens and

Process Step Hazards

Multiplication of pathogens and

Multiplication of pathogens and

Multiplication of pathogens and

Multiplication of pathogens and

Process Step Hazards

Multiplication of pathogens and

Pumping And Mixing Multiplication of pathogens and

Multiplication of pathogens and

Residues and chemical

Multiplication of pathogens and

Multiplication of pathogens and

Process Step Hazards

Multiplication of pathogens and

Verified By Date Verified

HACCP DECISION TREE

Q1. Do control measures exist?

Modify step, process or product

Q1a. Is control necessary at this step for safety?

Q2. Is the step specifically designed to eliminate or reduce the likely

Q3.Could contamination with identified hazard(s) occur in excess of

Q4.Will a subsequent step eliminate the identified hazard(s) or reduce their

* Stop and proceed with the next identified hazard(s)

HACCP Study for Stirred Yogurt NRC: Decision Tree

Process Step Hazards Decision Tree

Multiplication of pathogens and spoilage organisms possible

Multiplication of pathogens and spoilage organisms possible

3A P Foreign matter 2 Filters in CIP system, enclosed covered equipment Y N N N

Multiplication of pathogens and spoilage organisms possible

3C C Residues and chemical contamination 2 Cleaning systems checked and verified. Y N N N

Processing (including pre heating,

Multiplication of pathogens and spoilage organisms possible

5C C Residues and chemical contamination 2 Cleaning systems checked and verified. Y N N N