Practical work

EVALUATION OF POTENTIAL HAZARDS IN THE MANUFACTURE

OF BEVERAGES
Purpose: to assess the potential risks to the technological process of beverage production.
Tasks:
1. Design a product description for the selected drink.
2. Develop flow diagram.
3. Write and describe the PRP programs required for the drink factory.
4. Identify potential hazards at the stages of the technological process, classified by risk
group:
 biological;
 chemical;
 physical.
5. Complete the risk assessment table. Use a risk matrix and risk assessment model for
hazard assessment.
6. Complete the CCP identification table and HACCP plan include all process stages
identified for potential hazards, including those not the CCP
7. Use the Decision Tree to identify the CCP.
RISK MATRIX
High 4 5 6 7
Real 3 4 5 6
Low 2 3 4 5
Probability
Very low 1 2 3 4
Very limited Moderate Serious Very serious
Effect

Risk category 1: no additional measuring instruments or control devices are

required at each stage of the process;
2. and 3. risk category: control point.
Risk category  4: CCP (critical control point).
DECISION TREE
 PRODUCT DESCRIPTION

1. Product name Milk

2. Important product characteristics of end Dry matter= % 12,6, protein= % 3,4, fat=%
product (e.g. aw, pH, etc.) 3,7, lactose= % 4,7, mineral= % 0,7
pH= 6.6- 6.8, aw= > 0,98

3. How the product is to be used The product is ready to use as purchased

4. Packaging glass bottles, plastic coated paper board, blow

mold nonreturnable poly- ethylene (PE)
containers, plastic pouches, and returnable
rigid polycarbonate containers.
5. Shelf-life once opened, all milk lasts 4-7 days past its
printed date, if refrigerated

6. Where the product will be sold All markets

7. Labelling instructions  Name of the food

 Net quantity of contents
 Name and location of the food
business
 List of ingredients if the food is
comprised of more than one
ingredient
 “Nutrition Facts” panel (for
packaged products sold at retail)
 Allergen disclosure

8. Special distribution control In places of temperate climate and in sub-

temperate conditions raw milk is
distributed directly to consumers. A short
period lapses between production and
consumption, the raw milk may be
distributed provided the temperature of
milk does not go beyond 10°C at delivery.

Product Identification
The milk leaving the factory can be consumed without the need for any
processing. Suitable as a beverage or for cooking/dessert making. Since it
contains lactose, it is suitable for the consumer group with lactose tolerance.
 PRODUCT INGREDIENTS AND INCOMING MATERIAL

Raw milk

RISK ASSESSMENT

Process step Identified hazard Risk assessment Control measures

FILTER CHEMICAL: POISONING TREATMENT OF

COPPER, CADMIUM, FROM THIS USED WATER
MERCURY AND LEAD ACCUMULATION

PASTEURIZATION PHYSICAL: INFECTION -ATTENTION TO

(CCP) INSECT AFTER EQUIPMENT
CONTAMINATION PASTEURIZATION CLEANLINESS
FROM EQUIPMENT AND GROWTH OF -ATTENTION IS
PAID TO THE
CONTAMINATION BACTERIA
RESIDUE OF
CHEMICAL: CLEANING
CLEANER/SANITIZER MATERIAL
RESIDUES - SPORE-FORMING
NITRATES, MICROORGANISMS
PHOSPHATES, ARE INHIBITED BY
CHLORINATED LOW PH
ORGANIC -  Milk contain
BIOLOGICAL: harmful
HIGH HEAT microorganisms such
TREATMENTS CAN as Salmonella,
CAUSE SOME SPORES Escherichia coli,
TO FORM Listeria
FORMATION OF monocytogenes,
HARMFUL Staphylococcus
MICROORGANISMS aureus, Yersinia
enterocolitica,
Bacillus cereus,
 Clostridium
botulinum,
Mycobacterium bovis,
Brucella
abortus and Brucella
melitensis. Coxiella
burnetii present in
milk, the most heat-
resistant organism is
of public health
significance. There
are high chances of
improper microbial
inactivation if
pasteurization
parameter not
followed correctly.

HOMOGENIZATION PHYSICAL: -EQUIPMENT

METAL FRAGMENTS, CLEANING
SUCH AS BOLTS, NUTS, - SOUNDNESS
BAG CLIPS/LOCKS CHECK OF
CHEMICAL: METAL
EQUIPMENTS, EQUIPMENT
CLEANING - SUITABLE
CHEMICALS, TEMPERATURE
LUBRICANTS, BOILER CONDITIONS TO
ADDITIVES, WATER PREVENT
TREATMENT PATHOGEN
ADDITIVES, OTHERS FORMATION
BIOLOGICAL:
PATHOGENIC
BACTERIA, VIRUSES
OR
PARASITES/PROTOZOA
COLD STORAGE PHYSICAL: - PERSONNEL
Personal effects, such as SHOULD NOT
jewellery, earrings, WEAR JEWELRY
buttons, pens - PERSONNEL
BIOLOGICAL: HYGIENE
BACTERIAL SHOULD BE
CONTAMINATION IN CONSIDERED.
WAREHOUSE
 CCP identification table
Answers to decision tree
CCP yes/no
Process step Identified hazard Hazard description Control measure questions
1 2 3 4
PASTEURIZATION Microbiological microbial growth due to Suitable temperature yes yes yes yes
contamination unsuitable temperature conditions are provided to
prevent the formation of
bacteria.
 HACCP plan
Process step Hazard Control measure Critical Monitoring Corrective HACCP
(highlight process Preventiv Contr limit What? How? Frequency Who? action records
stages that are e measure ol
CCP) point

FILTER Chemical TREATM low Daily regular water use

hazards ENT OF inspection should be
USED recorded
WATER in
appropria
te
conditions
PASTEURIZATI PHYSIC ATTENTI hıgh regular regular
ON AL: ON TO equipment temperat
EQUIPME CCP!
EQUIPM cleaning, ure
NT
ENT CLEANLI suitable control
CONTA NESS, temperature to
MINATI Milk prevent spores
ON contain and
CHEMIC harmful microorganisms
AL: microorga from forming
CLEANE nisms,
R/SANIT
IZER
RESIDU
ES
BIOLOG
ICAL:
 FORMA
TION OF
HARMF
UL
MICROO
RGANIS
MS

HOMOGENIZAT PHYSIC SOUNDN medıum regular regular

ION AL: ESS inspection of temperat
METAL CHECK especially metal ure
FRAGM OF equipment, control
ENTS METAL suitable
EQUIPM temperature
CHEMIC
ENT conditions to
AL:
CLEANI - prevent
NG SUITABL pathogen
CHEMIC E formation
ALS TEMPER
BIOLOG ATURE
ICAL: CONDITI
PATHOG ONS TO
ENIC PREVEN
BACTER T
IA, PATHOG
VIRUSES EN
OR FORMA
PARASIT TION
ES
 COLD PHYSICA PERSONN low Personnel should hygiene
STORAGE L: EL be informed informati
Personal HYGIENE about hygiene on control
effects SHOULD
BIOLOGI BE
CAL: CONSIDE
RED
BACTERI
AL
CONTAM
INATION
 Process flow
The whole process can be classified into diverse steps that include milk collection
from the cattle, transportation to processing plants, clarification,
homogenization, pasteurization and finally packing of the milk. These processes
are done through the milk processing equipments with efficient and natural manner.

FLOW DIAGRAM

Raw
milk
receivi
ng

FILT
ER

PASTE
URIZA
TION
(CCP)

HOMO
GENIZ
ATION

COLD
STORA