AN INDUSTRIAL TRAINING REPORT CARRIED OUT AT JESA FARM DIARY

FROM 19th/JUNE /2023 TO 20th/august/2023

 DECLARATION

I KWAGALA JOSHUA declare that the information contained in this report is true and is
based on my personal research and the activities done at JESA. The reference books where extra
research is made in order to come up with the report are clearly stated in the reference part.

This industrial training report has been submitted to the department or Agricultural and
Biosystems Engineering, and a partial fulfillment of the required for the award of a bachelors
degree in bioprocessing engineering at Makerere University.

Signature: …………………

Date: ………………………

DEDICATION

I dedicate this report to beloved parents, The family of Bishop Ivan Lugoloobi who work hard
for my studied, my sisters for the continued support to me as I am persuing my career. I also
dedicate it to my lecturers who have shared there knowledge with me in the theoretical and
practical field.

May the almighty God bless them so much.

CHAPTER ONE

1. INTRODUCTION

1.1 INTRODUCTION TO INDUSTRIAL TRAINING.

Industrial Training: This can be defined as the training programme that is provided during the
course study, with the sole purpose of delivering on the field training or practical experience to
students.
1.1.1 OBJECTIVES OF THE INDUSTRIAL TRAINING

To enable students create a connection between the theory studied at compass and the practical
done at the industry.

To expose students to real work environment and gain knowledge in writing technical reports

To develop skills and techniques directly applicable to their carriers

To create an interaction between students and the future employees or worker mates

To develop different soft skills for example communication skills, problem solving etc

To create and maintain a close relationship between the universities/ institutions and operating
firms or companies

1.2 COMPANY PROFILE

Jesa Farm Dairy is a family owned dairy founded in 1989 by Mr. James Mulwana. Jesa
produces dairy products which include; UHT Milk, Fresh Pasteurized Milk, UHT Milk
Flavored with Chocolate, Vanilla or Straw berry food grade flavors, Yoghurt: both plane and
flavoured i.e (vanilla, straw berry, mixed berry, toffee) and fruit yoghurt (peach and passion,
blue berry, frui salads etc),

Butter, and Fresh Cream, Juice. Jesa products are of a high quality and at a manageable cost.

1.2.1 COMPANY LOCATION

Jesa Farm Dairy Ltd. is Located in Wakiso district approximately 50 km northwest of Kampala.

1.2.2 COMPANY ENGAGEMENT

1.2.2.1 DAIRY FARMING

This is carried out on 600Hectares of land on which a herd of over 600 Friesian animals are
raised under modern animal husbandry. Most of the feed for the animals is also produced at the
farm. All of the milk from the farm goes to the dairy which is also located on the farm. This is
something unique about JESA, because all of the other dairy plants rely 100% on purchased raw
milk.
1.2.2.2 DAIRY PROCESSING
These operations commenced in 1994. Producing our own milk at our farm enables us to
achieve a high quality, wholesome milk, something you can taste in our products.

The dairy plant currently processes 120000 Litres of milk a day. In addition to the milk from its
farm, the remainder of the raw milk comes from 145 out-growers from the vicinity of the farm
and beyond, whose milk is selected after meeting strict quality parameters. These range from
small scale farmers who supply 5 litres a day to bulk suppliers who deliver over 15,000 litres a
day.

By providing a ready market for farmers’ milk, JESA has had a positive impact on the
community in which it operates. The income levels of many households in the area have
increased and dairying is now seen as a real business.

JESA also provides its suppliers with some farm extension services in the form of vaccines,
bulls, and training on milk handling among other things.

The market for JESA products is primarily within Uganda, Sudan and Kenya. Customers
include all the major supermarkets and hotels as well as the international catering company
called Newrest Uganda In-flight Services which supplies our products to leading airlines such as
KLM and Brussels Airline. JESA is seeking distribution throughout the region.

JESA is one of the certified FOOD companies in the country – a testament to the company’s
commitment to producing safe, high quality products for its customers. JESA is also Halal
certified and all its products have been certified under the UNBS Q-mark system.

1.2.3 COMPANY VISION

To be the premier provider of selected value added Dairy products to the East African
consumer.

1.2.4 COMPANY MISSION

To consistently produce delicious and safe Dairy products that deliver improved nutrition and
wellness to our customers.
1.2.5 COMPANY VALUES
To foster a safe, open, trusting team environment in which individuals initiate, mutual respect,
integrity, and personal dignity are promoted and rewarded.

Commitment to innovation in our products to ensure we are the preferred supplier of our
customer.

Commitment to integrity in our business practices with all our stakeholders.

Commitment to ongoing education and development as we strive for continuous improvement in

the quality of everything we do.

Recognition to our responsibility for stewardship of the environment and to be a contributing

partner in our communities.

1.2.6 COMPANY FOOD SAFETY POLICY

Jesa Dairy Farm Ltd is a food Company specializing in the production of milk and milk
products and is committed to ensuring that all products meet food safety requirements.

The management and staff at Jesa Dairy Farm Ltd commit to taking all necessary measures to
ensure the safety of all our products sold to customers and consumers.

All aspects of our business including purchasing goods inwards, storage, preparation, handling
and delivery of our products are carried out to the highest standards of food safety and hygiene.
We are committed to achieving full compliance with current and international standards,
regulations, legislations – FSSC 22000; US 130: 1999 HACCP systems requirements; US 163:

2000 Code of hygienic practice for milk products; US ISO 22000:2005, the codex Alimentarius
– and all regulatory and statutory requirements and establishing, maintaining, documenting &
improving a food safety management system.

To achieve this overall policy Jesa Dairy Farm Ltd commits to providing adequate resources,
including finance, personnel, premises, staff facilities and equipment to assure food safety All
employees are adequately trained, are responsible for the quality of their own work and are
committed to providing a high quality service
Procedures are followed to ensure the food safety policy is effectively implemented and
maintained.

The food safety policy shall be reviewed at least annually for continued suitability, relevance
and effectiveness in the food safety management review meeting.

It is communicated through training and is displayed in strategic places throughout the whole
farm.

Composition of the cow’s milk.

Quantitative composition of the milk

Main constituent Limits of variation Mean value
Water 85.5-89.5 87.5
Total solids 10.5-14.5 13.0
Fat 2.5-6.0 3.9
Proteins 2.9-5.0 3.4
Lactose 3.6-5.5 4.8
Minerals 0.6-0.9 0.8

Physical chemical properties of cows’ milk.

Cows’ milk consists of about 87% water and 13%dry substance. The dry substance is suspended
or dissolved in water. Depending on the type of solids there are different distribution systems of
them in the water phase.

Physical chemical status of cow’s milk.

Average composition%
Moisture 87.0
Fat 4.0
Proteins 3.5
Lactose 4.7
Ash 0.8

Chemical structure of milk fat

Milk fat is liquid when milk leaves the udder at 37oC, therefore fat globules can easily change
there shape when exposed to moderate mechanical treatment. All fats belong to esters which are
compounds of alcohols and acids. Milk fat is a mixture of different fatty acid esters
(triglycerides) which composed of an alcohol called glycerol and various fatty acid. Fatty acids
make up 90% of the milk fat.
A fatty acid molecule is composed of a hydrocarbon chain and a carboxyl group. Each glycerol
molecule can bind three fatty acid molecules .

The table shows lists of most important fatty acids in milk fat triglycerides.

Principle fatty acids in milk fat

Fatty acid % of total fatty acid content Melting point
Saturated
Butyric acid 3.0-4.5 -7.9
Caproic acid 1.3-2.2 -1.5
Caprylic acid 0.8-2.5 +16.5
Capric acid 1.8-3.8 +31.4
Lauric acid 2.0-5.0 +43.6
Myristic acid 7.0-11.0 +53.8
Palmitic acid 25.0-29.0 +62.6
Stearic acid 7.0-3.0 +69.3
Unsaturated
Oleic acid 30.0-40.0 +14.0
Linoleic acid 2.0-3.0 -5.0
Linolenic acid Up to 1.0 -5.0
Arachidonic acid Up to 1.0 -49.5

PROTEINS IN MILK

A protein molecule consists of one or more interlinked chains of amino acids, where amino acids
are arranged in a specific order. A protein molecule usually 100-200 linked amino acids .

Classes of milk proteins

Milk contains hundreds of types of proteins most of them in very small amounts. They can be
classified in various ways according to their chemical or physical properties and their biological
functions .

Casein

Casein is a group name for the dominant class of proteins. They easily form polymers containing
several identical or different types of molecules. Due to the abundance of ionisable groups and
hydrophobic and hydrophilic sites in the casein molecule, the molecular polymers formed by the
caseins are very special. The polymers are built up of hundreds of and thousand of individual
molecules and form a colloidal solution, which is what gives skimmilk its whitish blue tinge.

Casein protein Conc. In milk g/kg % of total protein w/w

 Alpha (s1)- casein 10.0 30.6

Alpha (s2)- casein 2.6 8.0

Beta- casein 10.1 30.8

Kappa- casein 3.3 10.1

Total casein 26.0 79.5

Whey proteins

This is the name commonly applied to milk serum proteins. If the casein is removed from skim
milk by some precipitation method, there remains in solution a group of proteins called serum
proteins.

As long as they are not denatured by heat, they are not precipitated at their isoelectric points.

When milk is heated, some of the whey proteins denatured and form complexes with casein.
Thereby decreasing the ability of casein to be attacked by rennet and to bind calcium.

Whey proteins are alpha lactalbumin in particular have very high nutritional values. There
amino acid composition is very close to that which is regarded as a biological optimum.

Whey proteins derivatives are widely used in the food industry.

ENZYMES IN MILK

Enzymes Are biological compounds that speed up the rate of a biochemical reaction but remains
unchanged at the end of the reaction.

Two factors which strongly influence enzymatic action are temperature and pH.

Enzymes are most active in an optimum temperature range between 25 and 50°C. Their activity
drops if the temperature is increased beyond optimum, ceasing altogether somewhere between
50 and 120°C. At these temperatures the enzymes are more or less completely denatured

(inactivated).

Different enzymes have different deactivation temperatures.

The enzymes in milk come either from the cow’s udder or from bacteria. The former are normal
constituents of milk and are called normal enzymes. The latter, bacteria enzymes, vary in
abundance and and size according to the nature and size of the bacterial population . Several of
the enzymes in milk are utilized for quality testing and control. Among the more important ones
are peroxidase, catalase, phosphatase and lipase.

Peroxidase. This enzyme transfers oxygen from hydrogen peroxide to other readily oxidisable
substances. This enzyme is inactivated if the milk is heated to 80oC for a few seconds. This can
be used to prove the presence of peroxidase in the milk and thereby check wether or not a
pasteurization temperature has been reached. This can also be called the storch’s test.

Catalase. Catalase splits hydrogen peroxide into water and free oxygen. By determining the
amount of oxygen that the enzyme can release in milk, its possible to estimate the catalase
content of the milk and learn wether or not the milk can come from an animal with a healthy
udder. Milk from diseased udder has a high catalase content while milk from a fresh udder
contains little content.

Phosphatase: Phosphatase has the property of being able to splint certain phosphoric acid esters
into phosphoric acid and the corresponding alcohols. The presence of phosphoric acid can be
detected by adding phosphoric acid ester and a reagent that changes color when it reacts with the
alcohol. A change in color reveals that the milk contains phophatase. Phosphatase is destroyed
by ordinary pastuerisation (72oC for 15 to 20 seconds). The phosphatase test should be
performed immediately after heat treatment. Failing that, the milk should be chilled to about 5 oC
and kept at that temperature until analysed.

Lipase. Lipase splints fat into glycerol and free fatty acids. Excess free fatty acids in milk and
milk products result into rancid taste. The action of this enzyme seem in most cases to be very
week though milk from certain cows may show strong lipase activity. The quantity of lipase in
milk is believed to increase towards the end of the lactation cycle. This enzyme is to a great
extent inactivated by pasteurization but higher temperatures are required for inactivation.

Lactose . This is a sugar found in only milk. lactose is a disaccharide made up of glucose and
galactose. When it is attacked by lactic acid bacteria, the bacteria contains an enzyme called
lactase which attacks lactose into glucose and galactose. Other enzymes from the lactic acid
bacteria then attack the glucose and galactose, which are converted via intermediary reactions
into lactic acid.

VITAMINS IN MILK
Vitamins are organic substances which occur in very small concentrations in both plants and
animals. Milk contains many vitamins among the best known are A, B1. B2, C and D. Vitamin A
and D are soluble in fat, or fat solvents while the others are soluble in water.

Vitamin Amount in one litre of milk, mg

A 0.2-2
B1 0.4
B2 1.7
C 5
D 0.002

MINERALS AND SALTS IN MILK.

Milk contains a number of minerals. The total concentration is less than 1%.

Mineral salts occur in solution in milk serum or in casein compounds. The most important salts
are those of sodium, calcium, potassium and magnesium. They occur as phosphates, chlorides,
citrates and caseinates. Potassium and calcium salt are the most abundant in normal milk. the
amount of salts present are not constant towards the end of lactation and even more so in the case
of udder diseases. The sodium chloride content increases and gives the milk a salty taste while
the amounts of other salts are correspondingly reduced.

JESA suppliers

Milk is the largest raw material that is used at JESA diary. This implies that a big supply for the
raw material is needed. The suppliers are:

JESA Farm.

JESA farm is one of the suppliers of milk at the Diary plant. Though the amount of milk supplied
by it is too little that calls for more suppliers. Jesa Farm supplies about 5000 litres of milk per
day.

Small Scale suppliers:

These are suppliers that supply above 5litres of milk per day. They deliver it in cans. These
suppliers are basically local suppliers (live around the industry). The also transport their milk of
motocycles and bicycles.

Large Scale Suppliers:

These are the ones that supply the milk in trucks. They supply the largest percentage of the milk
that is processed in the industry. These suppliers have different collection centers where they
collect the milk from and bring it at the industry.

RAW MILK INTAKE.

After being checked by the quality controller on the gate, the truck Is properly disinfected and
then allowed into the industry. It is driven up to the offloading station. The way the truck parks
at the offloading station is also necessary. It is parked in such a way that the front tires are tilted
higher than the lower ones. This is done to make the outflow of the milk from the truck easy.

Cleaning of sieves (1 and 2) are cleaned used water at a higher pressure. this is done in order to
remove the debris so that the flow rate increases. This acts a critical control point for raw milk
intake process.

The milk is removed from the truck using a horse pipe. It is connected at the behind valve on the
Truck. It is then cleaned in order to avoid contamination.

The initial flow meter reading is recorded from the flow meter. The process of intake then starts
whereby milk is drained from the track tank by connecting to a pump.

The system first does pre pushing whereby it pushes about 90litres of water from the system

As it flows past the pump it is de aerated, filtered and then chilled by cold water in a heat
exchanger. De aeration is done in the vacuum tank. This is done to remove the air. The cooling is
effected by using water as a cooling medium. The efficiency of water for cooling is enhanced by
adding glycol. This acts as an ant freezing agent so that water can remain in liquid state when
chilled to -1 to -2oc. By the time the milk reaches the storage tank or silo, it is always at a
temperature of ≤4oc.

After offloading, a Final push is done where water of about 250litres is passed through the
system to push the remaining milk into the raw milk storage tank.

The final flow meter reading is noted.

The amount of milk offloaded is by getting the difference between the final flow meter reading
and the initial flow meter reading and its obtained in litres.

After this, CIP of the system is done. This is done by connecting the raw milk inlet channel to
the CIP line.
The silos contain an argitator at there lower part that argitate the milk in order to prevent oudor
formation, uniform temperature distribution and also preventing the fat from settling at the
bottom of the silo. . If agitation is done at high speed, the milk incorporates air which would
cause oxidative rancidity of the fat hence off odour development.

The silos and tanks are lagged to insulate them against heat loss. Maximum holding time for
milk in tanks and silos is 48hours before processing. Silos hold large volumes of milk
(400000ltrs and 80000litres)

Quality at the gate Lab

This is where analysis was made on the milk samples immediately they arrive at the industry.
This was done on both the tracks and cans. The outcome of the analysis may give a negative or a
positive result. When the outcome was positive, the tracks were allowed to enter and offload the
milk and likewise the cans were offloaded. When the outcome of the analysis was negative, the
trucks were given rejection reports and they took back the milk. The suppliers of milk in the
cans were also ordered to take back the milk.

A lot of tests are carried out at the gate in order to ensure that the milk that is entered in the
industry is of required quality. The tests include: organo leptic test, somatic cells count, density,
temperature, pH, Alcohol test, Batter fat, Titratable Acidity, clot on Boiling (COB), Resazurin
test, Antibiotic test, adulterants, added water, sediment test, solid non fat, proteins, lactose,
salts, formalin,

Titratable Acidity .

This test is done to analyze the percentage of lactic acid in the milk sample. The normal milk
titratable acidity is 0.14-0.17% Lactic acid. When it is beyond that range, the milk will be too
acidic and increase in acidity may lead to:

Change in the test of the milk i.e it will have a sour test due to reduced pH

The low pH in the milk sample favours optimum conditions for growth of microorganisms i.e
lactic Acid Bacteria that grows best at low pH levels
Requirements: Petri dish, pipette, phenolphthalein indicator, 0.1M sodium hydrxide, 0.1M
hydrochloric Acid, retort stand, dropper.

Procedure for Titratable Acidity analysis.

1ml of the sample is pipetted and poured onto the Petri dish.

The initial volume of the standard solution of a 0.1M sodium hydroxide in the buirrete is noted

2 drops of phenolphthalein indicator are added and then titrated with a standard solution of a
0.1M sodium hydroxide untill When color of the milk in the petri dish has just changed from
white to purple

The volume of sodium hydroxide reacted is calculated and the value of titratable acidity is
( X −x)×0 . 1× 0 . 09× 100
calculated from TA= where X is the final buirrete reading and x is
volume of milk pipetted
the final buirette reading. 0.09 is the titration constant of the analysis.

Alcohol test.

This test is done in order to determine the stability of the proteins toward heat. If the stability of
the proteins is low, they will coagulate during processing. its is more likely to happen during
pasteurization because this is where heating takes place during processing . i.e they will separate
into casein and whey.

Requirements : buirette, pipette, petri dish, retort stand 70% or80% alcohol

Procedure for Alcohol test.

2ml of the milk to be analyzed are pipetted and transferred onto the petri dish.

2ml of 70% or 80% alcohol are also pipetted and added to the milk on the petri dish.

When the milk does not coagulate, it shows that the proteins are stable on heating and is recorded
as negative (-ve)

When it coagulates, it shows that the proteins are unstable on heating and is recorded as (+ve)
The milk that shows a positive on 80% alcohol, can not be sterilized. This simply means that it
can not be used to process ultra high temperature products.

The experiment can be done using an alcohol gun. When dipped vertically in the milk sample, it
can automatically measure 2ml of the sample and then pours both alcohol and the milk in equal
ratios.

Resazurin Test

This test is done to determine the microbial load in a sample. It is done using resazurin solution

On further incubation, it provides information about the rate of change of microbial load in a
sample.

The Resazurin test can also allow us know wether there are adulterants. Note: Resazurin
solution;

 can spend a maximum of eight hours from the time of preparation. This is simply because
it will lose its effectiveness
 Should be kept in light since it is light sensitive. This is because it gets oxidized when
exposed to light.

Procedure.

The Resazurin solution is first prepared by dissolving one tablet of resazurin in 50mills of
distilled water. The solution is kept out of reach of light.

The test tubes are rinsed using the milk samples in order to prevent contamination.

10ml of the milk samples are pitteted into the test tubes.

They are then heated in the water bath at a temperature of 38 for 5minutes.

The samples are then removed and added 1ml of resazurin solution.

The mixture is shaken very well so that they are homogeneous.

They are then heated in the water bath at temperature of 38 for 10minutes.
When the time has elapsed, the samples are removed from the water bath and the color change is
observed.

The number of Rez is determined by compairing the color of the samples with a chart

The number of Rez range from 0 to 6.

The milk that that is accepted is of Rez 6 and Rez 5

When no colour change is seen after 20 minutes of warming, it implies that there adulterants.

This is because adulterants tend to bind the microorganisms making it impossible for the
reaction to take place during the test hence the number of Rez will be constant at 6.

Resazurin disc No. Colour Milk grade Action taken

6 Blue Excellent Accept

5 Light blue Very good Accept

4 Purple Good Reject

3 Purple-pink Fair Reject

2 Light pink Poor Reject

1 Pink Bad Reject

0 White Very bad Reject

Batter fat test

This is done to determine the amount of batter fat in the milk. .

Requirements: Butyrometer, 91% Sulphuric Acid, Garber’s pipette, Gerber’s centrifuge, Amyl
Alcohol,

Procedure
10ml of sulphuric acid 91% concentrated is pipetted into the butyrometer.

This is followed by 10.75ml of the milk sample using a garber’s pipette. This is done in order
for the sulphuric acid to digest the milk sample. It breaks the components of the milk into smaller
particles

1ml of amyl alcohol is then added to the mixture in the butyrometer. Amyl alcohol is added to
separate the layers i.e the fat layer from the rest

The mixture is shaken gently and then centrifuged using a garber’s centrifuge for 4minutes.

The butyrometer is then removed from the centrifuge and the two layers formed can be
distinguished.

The amount of the fat can be read off from the graduated part of the butyrometer

Note; The butyrometers in the centrifuge are in pairs and in opposite direction.

pH test

This is done in order to determine the lactic acid concetration of the milk. The pH of the raw
milk should just be slightly acidic.

Low pH leads to detoriation of fresh milk

If the pH is low, the quality of the milk is poor which affects the growth of the culture hence
causing a longer fermentation.

Low pH affects the protein by breaking them down. The proteins will then be unstable hence
cant form a stable gel. A stable gel is one that gives a firm body or texture

A low pH makes the milk sour.

A high pH is also an indication of adulterants, udder diseases

Density

The density of the milk is determined using a lactometer

The density of row milk is between 28 to 36.

When there are adulterations by water, the density of the milk is low

When there are adulterations by powders and starches, the density of the milk is high.

Procedure.

A sample of milk whose density is to be determined is poured into a measuring cylinder.

A lactometer is then dipped into it and left to settle vertically.

The lactometer readings for the temperature t and density D are noted

The lactometer is calibrated at 29oC therefore the value measured is not considered final.

The temperature at which the density is measured is recorded as t.

The change in temperature dt is got by dt=29-t

Then the calibration factor F is got by F=0.2xdt

Then density=D-F for temperatures below calibration temperature and density=D+F for
temperatures above calibration temperature.

Milk testing
1. Warm the sample to 290C
2. Gently pour 85ml of the sample into the 100ml measuring cylinder to avoid
introduction of air.
3. Carefully and gently dip the clean and dry lactometer into the measuring cylinder
containing the sample
4. When the lactometer is now still in the sample, read off the value on the graduated
scale of the lactometer at the point where the sample cuts off the stem of the
lactometer.
5. Take the reading and record the result.
6. Pour the sample and clean the lactometer and the measuring cylinder.
Specification

1. For yoghurt mix range should be between

2. 1.055 – 1.065g/ml for sweetened yoghurt and 1.028 – 1040g/ml for non-sweetened
yoghurt
 3. Flavoured Milk: 1.055 – 1.065g/ml
4. Plain milk: 1.028 – 1.036g/ml
5. Sweetened milk: 1.055 – 1.065g/ml

Antibiotics test. This basically tests for Beta lactams, sulfonamides and tetracyclines.

When taken, antibiotics may cause anti biotic resistance in humans.

Milk containing antibiotics hinders fermentation (slow it down or even preventing it). this is
because they prevent growth of microbial cultures.

Anti biotics are tested using a milk antibiotic residues rapid test kit.

Procedure

200microlitres milk sample is pipetted into the reagent microwell and mixed well i.e by pipette
up and down.

The Microwell is put on the incubator and incubates for 3minutes at 38-42oC

The dipstick is inserted into the microwell after first incubation. Incubation for another 6minutes
at 38-42oC is allowed to take place.

The dipstick is taken out from the microwell and the sample pad is removed at the lower end and
the results are interpreted.

The interpretation is done according to the diagram below.

Somatic Cell count

This is done in order to check for any infections of the udder. Infections of the udder hinders
fermentation.

It may also raise the pH of the milk making it more alkaline.

This test is done using test strips and an activator solution. An activator solution is added to
activate the presence of the cells (increase there traceability).

To 1 drop of the milk sample is added 3 drops of the activator solution.

The color of the mixture id determined using a colour chart or a digital somatic cell count reader
wich measures in x1000cells per mill.

Solid Non Fat (SNF) .

This is a value that can be calculated using the values of the batter fat and the density.

SNF shows the amounts of the solids in the milk that are not fats. Their proportion in the milk
also determine the quality of the milk.

density
SNF=Batter fat × 0.22+ + 0.72
4

Likewise the components of the solids non fat (proteins, lactose, salts) can be calculated.

Proteins= SNF ×0.367

Lactose= SNF ×0.55

Salts= SNF ×0.083

NOTE, The following can be got automatically using a croscope

Adulterants .

The adulterants detected include formalin, Detergents, sodium chloride, sugar, glucose,
hydrogen peroxide, skim milk powder, Alzarin, Urea, starch and Nuetralizers.

Adulterants are detected using the milk adulteration test kit

Adulterants may raise the pH of the milk making it more alkaline.

Procedutre to taste for formalin

1. Take 2ml of raw milk sample in test tube

 2. Add 2 drops of reagent FM-1 and mix well
3. Add 1 ml of reagent FM-2 to the side of the test tube slowly
4. Observe the color of the ring formed at the junction and compare with the colour
chart.

Results reading

Absence of neutralizers = Brownish yellow colored ring

Presence of neutralizers = Purple/violet colored ring

Neutralizers testing procedure

1. Take 1ml of raw milk sample in test tube

2. Add 1ml of reagent N-1
3. Add 3 drops reagent N-2
4. Observe Color change of the solution and compare with the colour chart

Results reading

Absence of neutralizers = Light orange

Presence of neutralizers = Reddish pink

Note: The violet coloration does not appear usually when large of formalin present

Sediment test:

This is a test is used to determine the presence of foreign matter using a filter under pressure.
This is carried out on incoming raw milk from trucks or already within the silo and pasteurized
milk.
Procedure

Take 500ml of milk sample and adjust the temperature to 40oC and then cool to 20oC
Clean the sediment tester thoroughly with filtered water
Place a clean filter pad, with the name of the supplier into position
Pour the 500ml milk sample into the tester and let all the milk pass through the sediment
disc/pad.
Remove the filter pad and place it on a clean surface (parchment paper) to dry in a dust
free environment for at least 10 minutes.
 Grade the milk using the standard grading card.

Added Water.

The amount of water added in the milk is determined using a cryoscope. It works works on the
principle of the freezing point. The Value of the freezing point is depressed towards that of water
and it corresponds to a given percentage of added water.

Temperature;

The desired temperature for raw milk to be offloaded is 2-8oC.

Temperature beyond 8 will favour microbial growth.

Very low temperature are not desired since they can lead to freezing hence affecting the structure
of the proteins.

This is measured using a thermometer at the corresponding value is recorded directly.

Clot on boiling test (COB)

This is done in order to determine the stability of milk proteins, whether it can withstand heat
treatment. It is carried out on incoming raw milk in the trucks and on the already existing milk in
the silo.

PROCEDURE:

1. Pour the milk sample in the aluminum/ stainless steel container.

2. Using a pair of tongs to hold the container, heat the milk sample over the flame of the
Bunsen burner or any available heat source.

Observations/results
 If the milk clots, it is COB positive and hence cannot withstand heat treatment
 If it does not, then it is said to be COB negative and can further be processed into final
products
13 FREEZING POINT AND ADDED WATER
The freezing point of milk is regarded to be the most constant of all measurable properties of
milk that is a small adulteration of milk with water will cause a detectable elevation of the
freezing point of milk from its normal average value of -0.54oC close to 0oC. The addition of
water to milk not only reduces its quality, but also leads to spoilage or contamination that can
present a health hazard. The milk freezing point is measured using the Thermistor Cryoscope.

Requirements

Thermistor Cryoscope, Cryoscopy tubes,Graduated pipette (2-5 ml), Suitable cooling liquid for
the Cryoscope (33% aqueous solution of propylene glycol), Tube rack, Absorbent paper,

Calibration solution for the machine and anti-freeze solution: Calibration Standard “A” solution
(distilled water (-0.000°C freezing point)), Calibration Standard “B” solution (sodium chloride
solution (-0.600°C freezing point)). Put approximately 12 g of sodium chloride into an oven at
300°C for 5 hours or at 130°C for at least 24 hours. Cool down the sample in a desiccator.
Weigh exactly 10.161 g and dissolve into distilled water, bringing the volume up to 1,000 ml.
Let the solution stabilize for 24 hours,

ORGANOLEPTIC TEST CHARACTERISTICS

This test permits rapid detection and segregation of poor quality milk at the milk reception. This
test is exclusively subjective therefore the analyst should have a good sense of sight, smell, and
taste. It is cheap because no equipment is required and the test results are obtained instantly.

Note: Milk which cannot be adequately judged Organoleptically was always rapidly subjected to
more sensitive tests.

Steps followed in performing an organo leptic test

Once the sample has been availed in the laboratory, immediately observe and smell the milk. If
still unable to make a clear judgment, taste the milk, but do not swallow it instead spit the milk
sample into a sink and flush with water. The colour of the milk ranges from white to yellow
according to the coloration (carotene content) of the fat.
Note: Abnormal smell and taste may be due to; atmospheric taint like cowy/barnyodor,
physiological taints resulting from hormonal imbalance, cows in late lactation and spontaneous
rancidity, bacterial taints, chemical taints/discoloration, or even advanced acidification (pH less
than 6.4).

After the organoleptic test, the temperature of the milk is taken using a thermometer and it
should be less than 10oc.

CALIBRATION

CRYOSCOPE CALIBRATION.

Cryoscope calibration is done to ensure the cryoscope gives precise measurements. Its done
every after 2 days by the quality controller.

Procedure

1. Go to setup screen, check under calibration to ensure that the machine is set to the correct
calibration values, that is Calibration A reads 0.000oC and Calibration B reads -0.557oC
2. Pipette 3 sample vials each with 2.2ml of calibration solution A and 3 sample vials each
with 2.2ml of calibration solution B.
3. Place the 3 A-Standard sample vials on the vial stand separate from the 3 B-Standard to
avoid mix up.
Note: Rinse the vials with the respective calibration fluid to ensure that the vials are clean
and that the calibration liquids in the vial are 100% their value.

A-CALIBRATION

4. Place one sample vial with calibration liquid A in the cooling bath opening and select the
“measure” icon
When the measurement is done, record the value of the freezing point obtained on the cryoscope
calibration form (FRM/LAB-32) under 1 measure standard 0.

5. Place the second sample vial with calibration liquid A in the cooling bath opening and
select the “A-Calibration” icon.
When the measurement is done, record the value of the freezing point obtained on the cryoscope
calibration form (FRM/LAB-32) under calibrate standard 0.

6. Place the last sample vial with calibration liquid A in the cooling bath opening and select
the “measure” icon
When the measurement is done, record the value of the freezing point obtained on the cryoscope
calibration form (FRM/LAB-32) under 2 measure standard 0.

Note: the difference between the calibration value and the last measurement value should
not exceed 0.002 for an effective calibration.

B-CALIBRATION

7. Wipe the thermistor and stirrer with a lint free cotton wipe to avoid cross contamination
of the B-Standard samples with the previous A-Standard.
8. Place one sample vial with calibration liquid B in the cooling bath opening and select the
“measure” icon
When the measurement is done, record the value of the freezing point obtained on the cryoscope
calibration form (FRM/LAB-32) under 1 measure standard -0.557

9. Place the second sample vial with calibration liquid B in the cooling bath opening and
select the “B-Calibration” icon.
When the measurement is done, record the value of the freezing point obtained on the cryoscope
calibration form (FRM/LAB-32) under calibrate standard -0.557

10. Place the last sample vial with calibration liquid B in the cooling bath opening and select
the “measure” icon
When the measurement is done, record the value of the freezing point obtained on the cryoscope
calibration form (FRM/LAB-32) under 2 measure standard -0.557

Note: the difference between the calibration value and the last measurement value should
not exceed 0.002 for an effective calibration.

11. Check how effective the calibration was by running/ measuring a 2.2ml sample of the
standard control solution C of known freezing point -0.512o

pH METER CALIBRATION

pH calibration To ensure that pH Meter gives precise, accurate and concise measurements

it’s done once in a day and when deemed necessary

1. Rinse the sensor with distilled water before calibration

 2. Wipe the sensor dry with lint free cotton wipes
3. Immerse the sensor in buffer 7.0 solution first, press the “CAL” key and then the
“ENTER” key

The display blinks “CAL 1” and gives the pH reading for the first buffer used then gives a
prompt for the second buffer by displaying “CAL 2”

4. Remove the sensor, rinse it with distilled water and wipe it dry with the lint free wipe
5. Immerse the sensor in buffer 4.0 solution second, and press the “ENTER” key

The display blinks “CAL 2” and gives the pH reading for the second buffer used, calculates the
slope and finally displays “END CAL”

6. Remove the sensor, rinse it with distilled water and wipe it dry with the lint free wipe and
place it back in its storage solution.

NOTE: it’s prefered to draw a small amount of the buffer solutions into a clean beaker and
after calibration pour the solutions away to avoid buffer contamination

QUALITY CONTROL IN THE MICROBIOLOGY LAB

Microbiology is one of the essential analytical procedures that are put in place at JESA FARM
DIARY. This is done to ensure that the products released to the market for sale are free from
microorganisms

The microorganisms of interest and there appearance :

 Yeast and molds

Yeasts are green and molds are blue
 Staphylococcus aureus
Staphylococcus aureus appears violet
 Ecoli and coliforms
E.coli appears deep green(black) and coliforms are
deep red surrounded by gas.
 At JESA farm diary, Rapid plate count plates are used for plating the microorganisms.
Rapid yeast and mold count plate (YMC) is used for enumeration of yeasts and molds.

Staph Express count plate (STX) is used for enumeration of Staphylococcus aures. If the
colonies are different from violet, a staph express disk.

E.Coli / Coliform count plate (EC) is used for enumeration of E.Coli and Coliforms.

The Petrifilm Aerobic Count plate (AC) for enumeration of aerobic bacteria.

Optimum temperatures for growth

Yeasts and molds grow at room temperature, therefore they are incubated at a
temperature of about 25oC for 48hours

Staphylococcus aures, coliforms and E.Coli, and Aerobic microbes are incubated at 38 oC
for 48hours.

Microbiology analysis is done on the raw materials, products and the personnel in the
industry

General Procedure for plating

The rapid plate is removed from the pack

Its then labeled properly with the correct information i.e

product name, manufacturing date, expiry date and the date of plating.

A syringe is used to get 1ml of a sample and then transferred to the plate at a faster rate.

Microbiology analysis is done on

Personnel.

Microbiology analysis is done on the personnel in the industry every after a month.

This is done by taking samples from the people by swabbing using swabs.
The swaps are plated on all the plates i.e EC, AC, STX and YMC.

Air

Microbiology analysis is done on the air the production rooms. This is because Air can be can be
circulated with yeasts and molds which may contaminate the products therefore air plate counts
is done.

This is done by exposing the plate in air for like 30minutes and then incubated for 48hours.

Note: Yeast and molds can lead to bulging of the products even if they are taken to the cold
rooms.

If we find out that the air is circulated with microorganisms (yeasts and molds), fumigation is
done to kill them

Packaging material

We do plating of all the microorganisms of interest at JESA Farm Diary..

This is done by swabbing the material.

The swab contains dry mass of microorganisms, so it is dissolved in peptone water and then
plated.

Different products produced

Ultra High Temperature (UHT) Milk. We only do Total plate counts on UHT. This is because
its produced under aseptic environment. The few microorganisms that exist may be due to;

 Contamination by the packaging material.

 Errors by the microbiologist during the processes of plating and other interactions with
the sample
 Cleaning in place (CIP) was not perfect.

Yoghurt (all flavors)

Yoghurt contains a very high load of microorganisms because it is a cultured product. This is
why Total plate counts is not applicable to it. so we are interested in:

 Yeasts and molds

 Coliforms and E.Coli

Note: Due to the high cost of the staph express count plate,

we only do microbiology analysis of staphylococcus aureus on batter and cream. This is because
they are packed manually.

Procedures for microbiology analysis of staphylococcus aureus

Remove the STX petrifilms from their pack and for each sample to be analysed, label the STX
plate with the correct following sample information;

 Product name
 Production date
 Expiry date
 Pack size
 Time the sample was picked
 Date of plating
1. For both butter and fresh cream, using a 50ml beaker, weigh 1g of the sample and add
butterfield’s buffer sterile water to make a total of 10g. Then carefully stir the mixture
using a spatula that has been sterilised under UV light. From the mixture, draw 1ml using
the 3ml sterile syringe and aseptically transfer it to the STX petrifilm.

2. Place the plastic spreader on top of the inoculated petrifilm and spread the sample across
the 20cm2circular growth area.
3. Repeat steps 1-3 for all the samples that were picked

4. Place the inoculated plates in the incubator at a temperature of 35oC for 48 hours after
which the counting of the colony forming units is done.
 Procedure for microbiology analysis of Aerobic bacteria
Its done on Pasteurised milk (skimmed, semi-skimmed, full cream), UHT milk and juices,
Fresh, cream, Hand swabs, Equipment swabs and Final rinse water

Remove the AC petrifilms from their pack and for each sample to be analysed, label the AC
plate with the correct following sample information;
 Product name
 Production date
 Expiry date
 Pack size
 Time the sample was picked
 Date of plating
(a) For pasteurised milk, final rinse water, UHT milk and juices, using a 3ml sterile syringe,
draw 1ml of the sample and aseptically transfer it to the AC petrifilm.
(b) For Fresh cream, using a 50ml beaker, weigh 1g of the sample and add
butterfield’s buffer sterile water to make a total of 10g. Then carefully stir the
mixture using a spatula that has been sterilised under UV light. From the mixture,
draw 1ml using the 3ml sterile syringe and aseptically transfer it to the AC
petrifilm.
(c) For both the equipment and hand swabs, using a 50ml beaker, weigh 10g of
the butterfield’s buffer sterile water and place the cotton area of the swab into the
water to dissolve the contents on the swab. Then draw 1ml of the solution using
the 3ml sterile syringe and aseptically transfer it to the AC petrifilm.

Place the plastic spreader on top of the inoculated petrifilm and spread the sample across
the 20cm2circular growth area.
Repeat steps 1-3 for all the samples that were picked
Place the inoculated plates in the incubator at a temperature of 35oC for 48 hours after
which the counting of the colony forming units is done.
Microbiology analysis of Yeasts and molds

This is done on Pasteurised milk (skimmed, semi-skimmed, full cream), Yoghurt, Fresh
cream, Butter (unsalted and lightly salted), Hand swabs, Equipment swabs, Final rinse
water

Remove the RYM petrifilms from their pack and for each sample to be analysed, label the RYM
plate with the correct following sample information;

 Product name
 Production date
 Expiry date
 Pack size
 Time the sample was picked
 Date of plating
(a) For pasteurised milk and final rinse water, using a 3ml sterile syringe, draw
1ml of the sample and aseptically transfer it to the RYM petrifilm.

(b) For yoghurt, butter and fresh cream using a 50ml beaker, weigh 1g of the
sample and add butterfield’s buffer sterile water to make a total of 10g. Then
carefully stir the mixture using a spatula that has been sterilised under UV light.
From the mixture, draw 1ml using the 3ml sterile syringe and aseptically transfer
it to the RYM petrifilm.

(c) For both the equipment and hand swabs, using a 50ml beaker, weigh 10g of
the butterfield’s buffer sterile water and place the cotton area of the swab into the
water to dissolve the contents on the swab. Then draw 1ml of the solution using
the 3ml sterile syringe and aseptically transfer it to the RYM petrifilm.
 NOTE: Don’t exceed the given volume of the sample as this may cause
spreading growth.

Place the plastic spreader on top of the inoculated petrifilm and spread the sample
across the 20cm2circular growth area.
Repeat steps 1-3 for all the samples that were picked

NOTE: Remember to disinfect the hands with 70% ethanol in between the
steps to avoid cross contamination.

Place the inoculated plates in the incubator at a temperature of 25oC for 48 hours
after which the counting of the colony forming units is done.

Coliform plate count (CC)

This is a type of plate that is used to count all coliforms in the sample without differentiating
between genera. Coliforms by definition are a member of the family Enterobacteriacae which
ferments lactose to produce gas.

Basically, this count is used as a measure of fecal contamination in dairy products. This is
because fecal material is the major source of Coliforms. It is made up of a violet red bile lactose
nutrient, TTC indicator and a cold water soluble gelling agent.

Organisms can ferment lactose to produce gas bubbles trapped in gel net to the colonies. The bile
salts in the medium selects for the family Enterobacteriacae and the TTC indicator assists in
visualizing the colony.

The coliform count plate is applied on:

 fresh milk
 yoghurt
 cream
  butter.

Incubation is at 35⁰C for 48hours.

4. E.Coli Coliform count plate. (EC)

The EC plate counts all coliforms in a sample and differentiates E.Coli from Coliforms. E.Coli is
differentiated from other Coliforms by the BCIG reaction which colors E.Coli blue. The plate is
usually identical to the CC plate except that it has BCIG chromogens (color producing) indicator.

E.Coli is an indication of faecal contamination in dairy products.

This plate is applied on

 yoghurt,
 fresh milk, cream, butter.

Incubation is for 48 hours at 35⁰C.

LAMINAR AIR FLOW (LAF)

PROCEDURE:

Cleaning

1. Cleaning the outer surfaces daily with a clean dry cloth.

2. Cleaning of the inside of the LAF before and after every operation
 Switch on the UV lamp and the airflow for half an hour before starting work
 Switch off the UV light and decrease the airflow.
 Clean the workbench with a clean cloth and spray with 70% alcohol.
Operations

• Switch on the visible light

• After the completion of operation, wipe any spills and any residues.
Precautions

• Take care to prevent any damages to the integrity of the filter during cleaning.
• Switch on the airflow and UV light 30 minutes before of microbiological testing.
• Clean the LAF after every operation.
• Do not work when the UV light is on as it may cause damage to skin and eyes.
QUALITY CONTROL IN THE FRESH LAB

In the fresh lab, a lot of analysis was made on the fresh and the processed milk.

Silo Analysis.

This was done every day at 8:00am and 2:00pm.

This was done in order to provide awareness about the state of the milk the silos and provide the
best order to be followed while pumping out the milk from the silo for processing.

Parameters analyzed.

Resazurin: This test is done to determine the microbial load of the milk in the silo

On further incubation, it provides information about the rate of change of microbial load in a
sample. The silo with a high microbial load (lower number of Rez) is processed first.

Likewise the silo with a rapid rate of change in the microbial load is pumped first.

Batter fat level. The batter level of the milk in the silo contributes to the sweetness of the milk.
The higher the batter fat level, the sweeter the milk.

The batter fat is analyzed and in case of non conformances, milk from different silos is pumped
in different ratios to meet the required batter fat level.

Alcohol test. This is done in order to know the stability of proteins in the milk which is in the
silo

Temperature. The temperature of the milk in the silo is analyzed and it is expected to be below
10oC . this is because milk is chilled before being fed into the silo.

POUCH YOGHURT MONITORING

The flavors of pouch yoghurt produced include (vanilla, straw berry)

The pouch yoghurt produced was analyzed every after 30minutes.

A sample was taken from the machine and the following were analyzed:

Ph. When the ph goes below range, the taste of the yoghurt becomes sower. So it
was analyzed

Packaging integrity. This is done by:

 Checking the firmness of horizontal and vertical sealing.

  Checking the date codes (manufacturing and expirely dates)
 Details of the pouch yoghurt i.e vanilla, yoghurt

Viscosity. This was analyzed using a visco meter. This helped us to know how thick the yoghurt
produced is

Smoothness. This as determined by pouring the sample in the palm in order to know its texture.
Yoghurt that is free from solids gives a smooth texture.

Temperature. The temperature of pouch yoghurt produced is measured. This is because

temperature is a factor for microbial growth. High temperature will prolong the fermentation
which reduces the ph of the yoghurt hence making it sower.

If the temperatures are high, the pouch yoghurt produced is rapidly taken to the cold room. This
is done to further slow down the microbial rate.

Organo leptic test. This taste is done to analyse the colour, odour and taste of the yoghurt.

Documentation . the results of the analysis were noted in the yoghurt book and also written in the
online quality Assurance (QA) form.

FULL CREAM MILK MONITORING

Full cream milk has a shelf life of six days. It is packaged in 500g and 1000g pouches.

The products were analyzed every after 30minutes.

The parameters to analyse were:

Packaging integrity. This is done by:

 Checking the firmness of horizontal and vertical sealing.

 Checking the date codes (manufacturing and expirely dates)
 More details about the product i.e size and name.

Phosphatase test. This test was done to test for the effectiveness of pasteurization. This is
because it is pasteurized milk.

Organo leptic test: this test is done to an analyze the color, oduor and taste of the yoghurt.

Batter fat. This test was done to determine the batter fat level in the full cream milk. This is
because batter fat enhances the taste of the milk.

Weight verification. Using a weighing scale, the weight of the full cream milk is measured and if
out of range, the operators of the machine were informed to make adjustments in the machine in
order to fit in the required range.
 QUALITY ASSURANCE

In Quality assurance department, the following activities a done.

i. Raw material inspection

ii. Product Release
iii. Document control ( Developing SOPs and Reviewing SOPs)
iv. Data Trending
v. Internal Auditing/ suppliers Audits

i. Raw material inspection.

The raw materials inspected include:
 Ingredients
 Packaging materials
 Chemicals (cleaning)

Ingredients. The ingredients include:

 Stabilizers(starch)
 Sugar
 Flavors
 Fruit pulps
 Cultures
 Colors

The parameters monitored include:

 Odor
 Appearance
 Chemistry (pH)
  Microbiology
 Percentage of fruits for fruit pulps

Packaging materials.

The packaging materials are classified into 3 types.

 Primary packages
 Secondary packages
 tertiary packages

The primary packaging materials include Jerry cans, Tubs, Paper boards, cups, films, foils.

The analysis made on primary packages include

 Art work
 Dimensions
 Microbiology swabs
 The secondary packaging materials include clear covers, cartons.
 The tertiary packaging materials include Cartons, Shrink films.

Note: only Art work analysis is done on of the secondary and tertiary packaging materials.

Chemicals (cleaning). The cleaning chemicals used at JESA Farm Diary include

 Nitric Acid
 Sodium hydroxide
 Rustex.

The parameters monitored are concentrations and the Best Before date.

Product dispatch.
Different products are dispatched at different time intervals after production. Yoghurt is
dispatched two days after production. This is because there microbiology results are out and

UHT products are dispatched 7 days after there production . this Is because the microbiology
results for UHT are out after those days.

Fresh cream is dispatched the day its produced.

Butter, cream are dispatched two days after production because of the same reason.

During product dispatch, Analysis is done at the time of dispatch and a certificate of analysis is
written and given to the DHL which handles the supply chain and other whole salers.

PREREQUISITE PROGRAMMES AT JESA

Quality system policy.

Purpose. This program defines how management will insure products produced are safe, comply
with regulations, and meet customer expectations.

Expectations

Programmes should include but not limited to:

Management commitment to quality and food safety

Crisis management

Notification of change

Continous Improvement (KAIZEN)

Good manufacturing practices (GMPs) at JESA.

These activities are quality measures that help assure safe products are being produced
consistently. These aid the organization, mantainance, and operation of sanitary process and
environment in the industry.

They encompass a wide range of food safety procedures related to the diary products.
All the plant personnel, vistors, maintenance , and outside contractors are made aware of them.

Expectations of GMPs.

Program should include but not limited to:

Personnel hygiene/ hand washing.

Infectious / communicable diseases and wounds.

Employee practices i.e.

 Personal Protective equipments requires e.g hairnets, beard guards, gloves,shoes,

uniforms, earplugs.
 Eating, drinking, smoking.
 Jewerly and personal dress.

Facilities and ground expectations.

Storage of personal and food items.

Locker rooms

Daily housekeeping or cleaning to minimize contamination.

Food safety and Quality systems at JESA.

This is done at JESA in order to ensure raw materials and finished products meet all local and
federal food safety regulations as well as specifications.

Expectations

An assigned person or position responsible for maintaining the program.

Certificate of Analysis (COA) or certificate of comformance (COC).

 Facility should not allow chemicals, raw materials, or label material to be used in the
process without being accompanied by a guarantee that specification is met.
 A procedure addressing materials receipt and missing documents
Letters Of Guarantee (LOG)

An assurance is supplied stating that finished products meets regulatory compliance for specified

Documentation and Record control.

This control program ensures current and accurate information is distributed via documentation
throughout the plant. A document control policy is put in place and audited at JESA.

Expectations:

 Document retention times is defined.

 Good record keeping practices is followed.
 Documentation is adequately secured to reduce the risk of tampering.

Internal Audits

The industry follows a strict documented self auditing program of quality and food safety
programs, which involves the participation of all managers to be audit ready and in compliance.

Expectations:

 An assigned person or position responsible for managing the program.

 A written procedure and audit check list.
 The audit frequency
 A written report and documented corrective actions.
 Key performance indicators for the plant

Other prerequisite programs include.

 Traceability and recall

 Pest control programs
 Allergen Awareness or management program
 Foreign material and defect control
 Process control
 Line clearance
 Cleaning or Sanitation.
 Preventative maintenance
 Food defence or plant security
 Corrective Action system or customer complaints
 Microbiological control program

HAZARD ANALYSIS CRITICAL CONTROL POINTS (HACCP) At JESA

HACCP: is a systematic approach to ensure food safety by examining every step in a

food operation , identifying hazards and assessing their severity and risks and controlling
the hazards.

Benefits of HACCP.
It offers a rational approach to the control hazards in foods.
It avoids the many weaknesses inherent in inspectional approach.
It increases confidence in the food supply.
Its application reduces risk of foodborne diseases.
It leads to increased market access and reduction in production cost since there is reduced
recall or wastage of food.

Harzard analysis at JESA is therefore:

The identification of the potential hazards.
The risk of hazards (microbiological, chemical and physical) occurring, considering
 Potential sources and specific points of contamination
 The probability that microorganisms will survive and or multiply during
production, processing, storage and preparation for consumption
 The assessment of risks and severity of hazards identified.

All the steps of HACCP are clearly followed at JESA which include:
 Select the team
 Define the terms of reference
  Describe the product
 Identify intended use of product by consumer.
 Construct a flow diagram
 On site verification of flow diagram
 List all hazards associated with each processs step and list all measures
which will control the hazards.
 Apply the HACCP decision tree.
 Establish target levels and tolerances for each CCP
 Establish a monitoring system for each CCP
 Establish a corrective action plan
 Establish record keeping and documentation.
 Verification.
 Review HACCP plan.

Critical Contol Point CCP.

A critical control point is a location, practice, procedure or process at which
control can be exercised over one or more factors which, if controlled, could
minimizes or prevent a hazard.

The CCPs at JESA include;

Pasteurization at 85oC
Sterilization at 140 oC
Maintaining the cold room temperatures at below 4 oC.
Sanitizing the shoes at the point of entrance to the industry

PRODUCTION

PASTURIZATION

Milk Pasteurization: This is the process of heating milk to a specific temperature of 85oc for a
specified period of time in order to reduce the microorganisms or pathogens.

PROCESS OF RAW MILK PASTEURIZATION.

The Human manual Interface (HMI) is used to give commands to be system.

The Raw milk silo where the milk to be pasteurized is to be got is selected.

The pasteurization Tank where the pasteurized milk is to be fed is selected and ensured that it is
clean.

The system is first sanitized by sanitization water which is at a temperature of 95oC for ten
minutes.

Raw milk comes from the Silo into the balance tank. The balance tank controls the constant flow
of milk. Even when the milk is not pasteurized well, it goes back there.

Then its taken through the flow meter by the help of a product pump.

It is then taken to the preheating chamber where by the milk is warmed to about 55 oC-65 oC.

Then its taken through the Eco-clear which removes the bacteria and other foreign particles.

The Eco-clear uses centrifugal force to do the separation and it discharges them off every when
they reach a certain amount

It is then taken into the Eco-cream which separates the fat from the milk with the help of a
standardizer and according to the requirements of the end product.

UHT………………….3.7-3.8

Drinking yoghurt…….2.5

Flavoured milk………1.5-2.0

Fruit Yoghurt……….1.5

Lactose free………..3.6

The separation pressure in the Eco-clear has to be below 4bars.

Then the milk passes through the preheating chamber to the heating chamber where it is heated
by heat exchange to by the already pasteurized milk to a temperature of 75 oC. in the heating
chamber

It’s then taken into the homogenizer by help of a booster pump which grinds the fat particles
into finer particles in order to mix with the milk.
The homogenized milk comes back through the heating chamber and goes to the final heating
chamber where the milk is pasteurized at the pasteurization temperature of 85 oC by the help of
steam which heats up the water that heats the milk.

From the final heating chamber of the heat exchanger, it goes to the holding tubes for 20seconds
to maintain the temperature.

From the holding tubes it goes to the cooling chamber where it is cooled at a temperature of 4 oC
by the help of ice or chilling water.

After cooling, then it goes to the storage tank. (pasteurization storage tanks)

Importance of pasteurization.

It increases the shelf life

Value addition

Killing or reducing microorganisms.

After pasteurization, phosphatase test is carried out in order to check for its effectiveness.

Procedure for phopshatase test

Remove one strip from the bottle and reseal the cap

Note: Close the container immediately after removing the test strips. Never touch the
reaction zone of the test strip. Doing contrary to this will lead to wrong results

Dip the test strip into the milk. Take it out immediately
For the result, wait for 5 minutes
Results reading

1. Negative results = The test strip remains blue in color

2. Positive results = The test strip changes to green

SHELF LIFE OF PASTEURISED MILK.

Shelf life is the period of time during which food products remain safe, retain desired sensory,
chemical, physical and microbiological characteristics and maintain a composition that complies
with the label declaration when stored and handled under the recommended conditions. ie, shelf
life is considered as a period of time in which food products are stable and viable for
consumption.
The shelf life of pasteurized milk is always dependent on the quality of the raw milk. Naturally,
it is also most important that production conditions are technically and hygienically optimized,
and that the plant is properly managed.

Freshly pasteurized milk processed and packaged by Jesa farm dairy ltd has a shelf-life of 6
days when kept at 5 – 7 °C in an unopened package.

Physico-chemical analysis of pasteurized milk

This procedure aims at obtaining assurance that the pasteurized milk is fit for UHT processing
and the following control parameters are assessed (pH, T.A, Temp, density, butter fat, SNF, as
well as sensory attributes) and a record is made and kept in a controlled file. This also serves as
a release note for the machine operator to proceed with the subsequent processing procedures.
The note is normally issued out by the analyst (quality controller) on duty.

STERILIZATION

Milk Sterilization: This is the process of heating milk to a specific temperature of about 140oC
for a specified period of time in order to kill all the microorganisms or pathogens and the spores.

UHT is Ultra High Temperature. The sterilization system at JESA Farm Diary is capable of
sterilizing about 7500 litres per hour.

PROCESSES DURING UHT TREATMENT

The major processes involved during sterilization include:

1. Sterilisation
2. Production
3. Cleaning
The sterilization process starts with sterilization of the equipment to be used in the
process with the aseptic tank inclusive. This is done using sanitization water (water
heated by steam for 30 minutes)
In this unit milk is heated at a high temperatures of over 1400C. The main aim of this process is
to increase the shelf life of the milk and to remove all the microorganisms in the milk. Milk from
the UHT unit can last for over 6 months or 9 months on the market when it is still safe. This is
because the sterilization temperature is too high which kills all the microorganism making it hard
for any or even spores to survive.

STERILIZATION PROCESS

Pasteurised milk is received from one of the pasteurized milk storage tanks, the pump drives the
milk to the balance tank which balances the flow rate of the milk, balances the pressure at which
the milk is flowing.

A pump drives the milk from the balance tank to the holding pipes (Double pipe heat
exchangers) which are made in a double layer with the external pipe for holding water and the
internal pipe for milk. Here the milk is first preheated to 750C before it goes to the homogenizer
because fats are easily broken down at a high temperatue.

The milk proceeds to the homogenizer where the fats are broken down and the mixed uniformly
with the milk, The process is at hihgh pressure with the first stage pressure set at 160bars while
the second stage pressure is set at 40 bars.

The milk is returned from the homogenizer and its gradually heated to 930C in the first heating
zone then to 1040C and then to 1310C then to 1400C which is the CCP(Critical Ccontrol Point)
and from here the milk is then cooled through three zones upto an outlet temperature of 230C.
From here the milk is taken to the aseptic tajnk for storage before UHT filling and packing.

UHT MILK FILLING AND PACKING.

At the old plant UHT milk is packed in pouches in 500ml, using the UHT filling machine. The
machine receives 2000lt/h and packs 1800lt/hr.

The 200lt/hr is sent back to the balance tank as return. Filling machine is kpt sterile using sterile
air. The peroxide chamber keeps peroxide for sterilizing the packing machine, Squeezers remove
the peroxide from the film.
UV lamps dry the excess peroxides as well as killing microbes to avoid any contamination

The packaging material is a film that is made of polyethene with 5 layers, that cuts oof air
entrance and inserting the date.

IMPORTANT NOTES

 At the Critical Control Point (CCP), the milk is heated for only 4 seconds to kill all the
microorganisms and prevent it from being burnt.
 Heating of the milk is a stepwise process where steam from the boiler heats the water and
the water heats the milk. Its not advisable to heat the milk directly with milk because the
milk can be burnt easily since steam is at very high temperatures.
 The homogenizer has a valve that opens and pours the milk incase of an emergency.
 Ultra compressed air and steam filters trap all the microorganisms in the steam.

The pipes and tanks used in the process are made up of stainless steel. This is because of its good
properties which may include:

 It does not rust

 It does not corrode
 Its strong.

MAJOR EQUIPMENTS USED IN THE STERILIZATION PROCESS

1. Aseptic tank.

The major role of the aseptic tank is to to hold and store UHT sterilized milk for a given
period of

time before packing.

It has a capacity of 20000 litres

It has a cooling water jacket that is used for cooling the tank.

The aseptic tank has an agitator that mixes the milk and prevents fat or cream from floating
on top.
2. Homogeniser
This machine has got two stages, the first stage pressure that must be raised to 160 bars
and the first stage pressure that must be raised to 40 bars during processing.
It plays a major role of breaking down the fats and mixing them uniformly with the milk.
3. Balance tank
This is a tank of medium capacity whose work is to hold the milk as it flows so as to
balance the flowrate of the milk.
It balances the pressure at which the milk is flowing.
The balance tank has got a sensor at the opening lid that detects any opening on the lid
during processing.
4. Pumps
These have got different power ratings depending on their different functions.
They drive fluids ie milk pumps drive milk to their respective destinations, CIP pumps
drive chemicals for CIP like acid, caustic to their places of cleaning.
5. Double pipe heat exchangers.
These are made up of an external and an internal pipe interconnected, they are made up
of stainless steel. The outer pipe is for transporting water while the inner pipe is for
transporting milk.
It should be noted that each different section of these heat exchangers extends the milk to
a different temperature.
They play a role of raising or lowering the milk to a certain temperature.
6. Steam barriers
These are connected to the aseptic tank and are secondary safety measures that is Critical
Control Point, CCP.
7. Back pressure valve

This regulates the pressure of the milk before it goes to the aseptic tank.

8. Valves
These have a black outer colour on their top, they show different lights depending on
whether they are open or closed.
 They play a role of opening and closing the pipes during processing. Their mechanism is
influenced by compressed air.
9. Pre sterilization tank.
This is a medium sterilization tank that holds water that is used for sterilizing the system
before the UHT process starts.

PARAMETERS MONITORED DURING UHT STERILISATION.

 Product flowrate
 Water flowrate
 Steam pressure
 Hot point temperature
 Uht temperature(135-1400C)
 Product out temperature(23-270C)
 Homogeniser temperature
 Homegeniser in pressure in bars
 Homogeniser pressure, first stage
 Homogeniser pressure, second stage
 Steam capacity, V19%

Utilities used in UHT treatment.

 Clean soft water for cleaning materials, heating milk and processing.
 Power or electricity for running machines like homogenizer.
 Compressed air is used for opening and closing of the valves.
 Steam is used for boiling the water used to beat the milk.
 Raw materials i.e milk.

CIP OF THE SYSYTEM

The two types of CIP done are

  Full cleaning
 Aseptic cleaning
Full cleaning is done every after production . it takes about 8hours to be expired.
Aseptic cleaning is done if there is a problem during production . After doing Aseptic
CIP, production is resumed.

Aseptic filling and Packing of Ultra High Temperature products.

UHT products are packed aseptically using the Tetrapack machines i.e (Tetrapark A1 and
Tetrapark A3 )and the Liewest machine and Elecster. This is done because they are sterile
products

For tetrafino milk, sterilization is archived using hydrogen peroxide. This is because hydrogen
peroxide also has anti microbial properties. The hydrogen peroxide concentration is determined
using a hydrogen peroxide refractometer. Hydrogen peroxide is added to the machine at every
start of the machine. Generally, a concentration of about 34% is required.

Super heating air is used to dry the packaging film. It can also at the same time be used to kill be
microorganisms that survived hydrogen peroxide. The super heated air is maintained at
temperatures of less than 126oC and a pressure of 4bars.

The section is also filled with with Ultra Violet light. Its purpose is to prevent any form of
external disturbance during the filling process. During filling, the machine automatically
switches off its self due to asepsis

Aseptic parking For Elecster and Leiwest, is achieved through use of hydrogen peroxide as well
as super heating air. Furthermore, the hydrogen peroxide also washes away dust particles which
might have come along with the package film.

UHT UNFLAVOURED MILK

UHT: Ultra High Temperature.

UHT milk is the one which is subjected to very high temperature (thermal treatment) with an
aim of destroying all the microorganisms and the spores. UHT products are highly perishable
and easy to store since they can be stored at room temperature.

UHT products are produced by sterilizing the milk. this is done at a temperature of 135 to 140oC.
the temperature that acts as the Critical control point is 140 oC. the shelf life of UHT products is
between 3 to 6 months. Once the product is opened the first time, it needs to be refrigerated so
that it does not go bad

UHT UNFLAVOURED MILK FLOW DIAGRAM

UHT FLAVOURED MILK

The steps of production of flavoured milk are almost the same as the unflavoured milk. it only
differs at the stage of mixing.UHT flavored milk includes vanilla, strawberry, chocolate.

Flavoured milk mixing

Requirements

Milk, flavor, stabilizer, sugar

Flavoured milk is mixed using a blender.

A stabilizer is added to the milk using a blender.

This is then followed by the compound i.e vanilla, strawberry, chocolate.

Sugar is then added.

It is then left to hydrate for 45minutes

UHT PACKAGING INTEGRITY ONLINE TESTS

The packaging integrity tests carried out include

Conductivity test,

Red ink test,

Longtitudinal seal and strip Applicactor (LS and SA) evaluation.

TS tear down test

Note. There are many more packaging integrity tests but the ones listed above are the ones
of interest

Conductivity test. This test is used to check for any micro pores on the package. Basically, this
tests detects for the contact with aluminium layer.

Requirements.

A conductivity meter

Salt bath (10g NaCl/litre water)

Glass or plastic beaker

Procedure.

Empty the packages of the product

Cut packages in half but do not cut the longitudinal seal (LS)

Fold the package at the Longtudinal seal. (LS)

Place the package in the salt bath.

Pour salt solution into both halves of the package using beaker. This should be done without
weting the edges.

Place one probe in the bath and one in one half of the package

Check for continuity, repeat for other half of the package.

A deflection on a conductivity meter shows a that there are micropores (contact with aluminium
layer has issues).

Note; If any sample shows positive to conductivity, we continue with the red ink test.
RED INK TEST

This is perfomed when package shows positive to conductivity. This test indicates if there is any
rupture through the inside layers of PE, the Aluminium Foil and the PE laminate.

Requirements.

Red ink solution (saturated Erythrosine B in pure Isopropanol) – Pipette

Procedure.

 Empty packages of product

 Dry packages of water (before introducing ink)
 Cover all critical spots
 Exposure to the ink (5 minutes)
 Aspirate excess ink with pipette and dry with paper towel

TS TEAR DOWN test

It checks for the rupturing of the material layers and consistency of the seal quality.
Requirements.
– Stretch/Seal Pliers
– 10x magnifier with 0.2mm divisions (preferably illuminated
Procedure
TAKE two sample packages
– EMPTY packages of product
– CUT off the top and bottom Transversal Seals
– CUT no more than 1mm off the ends of the seals
– USE the Stretch Pliers, and (if necessary) the magnifier, to evaluate the seal quality

LONGTITUDINAL SEAL AND STRIP APPLICACTOR (LS AND SA)

EVALUATION.

What will be revealed:

 Measurement of Air Gap
 Evaluation of Heat Zone & Strip position
 Evidence of Channels
 Rupturing of material layers
Requirements
.10x magnifier with 0.2mm divisions (preferably illuminated)
– Zonoscope
 – Red ink solution (saturated Erythrosine B in pure Isopropanol)
– Vernier Caliper or ruler
Procedure
Take two packages and unfold to expose LS, DO NOT crease the strip
– Measure the strip position and heat zone
– Inject ink into one air gap, check for leaks through longitudinal creases
– Cut up the middle of the Strip remove overlap, pull off strip at 90 o
– Evaluate seal quality according to OM

MONITORING OF CIP CHEMICALS.

The CIP chemicals are monitored in order to make sure that the cleaning process is effective.

The CIP chemicals used include Nitric Acid and Caustic (sodium hydroxide)

Basically, the concentration of these chemicals is the main point of interest.

The steps follow as below.

i. Pre-rinse. This is done to remove the remaining milk. its done at 65oC.

ii. Alcali. Sodium hydroxide (caustic) is used to remove the proteneous fatty particles. This
is done at 75oC.
iii. Intermediatry rinse. This is done to remove the caustic residues

iv. Acid. Nitric Acid (60%) is used to remove the milk scales.

It is also done to stabilize the Ph after caustic wash. It is done at 65oC.

v. Final Rinse. This is done to remove the Acid. Its done at room temperature.
vi. Sanitization. This is water at a temperature of about 90oC.
vii. Drain.

NOTE: The final rinse water is taken to the lab by the quality controllers for analysis.

The conductivity of the final rinse water inside the instrument that has been washed is
proportional to the level of cleanliness.

The acceptable range for final rinse water is<=1.9milli Siemens

The acceptable range for hot water (sanitization water) is <=0.8milli Siemens.

CIP can be perfomed in many ways. The programs may include

Short CIP

Long CIP

Intermediate CIP

Final rinse

Procedure for Analysis of the chemical concentration of the CIP chemicals.

Sodium Hydroxide.
1. Collect the well mixed NaoH solution about 50mls
2. Cool to 200C
3. Pipette 1ml of the NaOH solution into a conical flask/beaker
4. Add 2-3 drops of the phenolphthalein indicator
5. Titrate against a 0.1N solution of HCl until the end point
6. Record the titre value
Formula:

% NaOH ¿ titre value∗normality of HCl∗relative molecular mass of NaOH

Nitric acid.

1. Collect the well mixed HNO3 solution about 50mls

2. Cool to 200C
3. Pipette 1ml of the HNO3 solution into a conical flask/beaker
4. Add 2-3 drops of the phenolphthalein indicator
7. Titrate against a 0.1N solution of NaOH until the end point
5. Record the titre value
Formula:

%HNO3¿ titre value∗normality of NaOH∗relative molecular mass of HNO3

10

Note:

1. For effective dairy processing CIPs, the range for cleaning solutions is as below
NaOH 1.5% to 2.5%

HNO3 0.5% to 2.0%

2. RFM of HNO3 = 63 and RFM of NaOH = 40

3. Lower concentrations of the cleaning solutions put the processed product at risk and
higher concentrations also have a corrosive effect on the machines in the long run.
Sholk therapy.

After sometime, the microorganisms become resistant to the CIP chemicals (caustic and nitric
Acid). This calls for sholk therapy.

Basically sholk therapy can be defined as killing of microorganisms that become resistant to CIP
chemicals. This is done using Hydrogen peroxide.

YOGHURT PRODUCTION.

Process of yoghurt formation. The process of yoghurt formation for different types of yoghurt is
basically the same though just slightly differs at some points.

The different types of yoghurt produced at JESA Farm Diary include:

 Drinking youghurt
 Fruit yoghurt
 Lactose free yoghurt
 Plain yoghurt
 Pouch yoghurt

Flavors used:

The flavors used include:

 Vanilla
 Strawberry
 Mixed berry
 Toffee

Fruit pulps used:

 Peach and passion.

 Fruit salads
 Blue berry

Lactic acid bacteria produce lactic acid which reduces the pH from the natural pH of milk (pH
6.6-6.8) to pH 4.6 and lower. Yoghurt is produced by lactic acid bacteria that grow best at about
40oC.
Process of yoghurt formation
Using a blender stabilizer, starch and sugar are added to the milk to make a yoghurt mixture.
This process is known as blending. The pasteurized milk is pumped via the tri blender where it’s
blended with stabilizers (starch) and sugar which acts as a sweetener.

After mixing, the mixture is left to hygrate for 45 minutes. During hydration, moisture is
asorbed from the starch . This process contributes to the smoothness of the yoghurt.

Process of yoghurt pasteurization.

The yoghurt mixture is taken into the pre heating chamber of the heat exchanger where its
temperature is raised to about 60oC. This is important because: it facilitates dissolving of sugar
and stabilizer, ensures attainment of the required temperatures for homogenization which lies
between 55-60oC.

It is then taken to the homogenizer so that the fat can be homogenously mixed in the yoghurt.
This ensures uniform distribution of fat globules. This process is normally carried out at 95oC
for 5 minutes. The temperature sensors on the system ensures optimum attainment of the
pasteurization temperature of the out flow product of the yoghurt mix. The yoghurt mix is then
rapidly cooled to inoculation temperature (40-45oC).

It is then taken back to the heating chamber and heated to a pasteurization temperature of about
91-99 oC.

It enters the holding tubes and passes through for 6minutes.

Its then taken back to the cooling chamber of the heat exchanger and cooled to a temperature of
about 40-44 oC.

Yoghurt formation process

The culture is then added from the top side of the tank. The cultures added are
Yoflex and Frresh Q4. The culture is about 200units/2500L and the protective culture is
100/2500L.

The argitator is put off and fermentation is allowed to take place in the fermentation tanks. The
temperature of the product in the tank is about 43oC. The incubation time is 4 to 6 hours while
monitoring the pH. Fermentation involves the degradation of milk sugars (lactose) and
destabilization of milk protein (casein) to attain an isoelectric pH of 4.6.

The yoghurt is considered ready if the pH drops to about 4.450-4.7. below a pH of 4.2, the
yoghurt will sower and if the curd is broken at a lower pH though in range, it may also sower
before packing. A sample is picked at different time intervals and taken the quality control lab
for analysis.

On breaking the curd, the argitator is turned on at a speed of 4rpm for 10 seconds. If the argitator
remains on after this time, the yoghurt will loose its body (it will become watery)

For pouched yoghurt, cooling of the product is necessary during the process of packing. This is
because cold yoghurt is thicker making it hard for it to be packed.

It is cooled to a temperature of about 25 oC.

The yoghurt is then packed and stored in the cold rooms at a temperature of 3 to 5

Yoghurt cultures

Streptococcus salivariussubsp. thermophilus and Lactobacillus delbrueckiisubsp. bulgaricus are

synergistic bacteria that are required in a yogurt starter culture. Streptococcus salivariussubsp.
thermophilus is a Gram-positive, cocci that has anoptimum growth temperature of 37oC.
Lactobacillus delbrueckiisubsp. bulgaricus is aGram-positive, nonspore forming, bacilli with an
optimum growth temperature of 45oC. The rate of acid production is much greater when these
bacteriaare used together, than if used separately.

The ratio of the organisms is generally 1:1. For production of yogurt, the milk is inoculated with
the starter culture, then incubated at 42oC (a compromise in the optimum growth temperatures of
both microorganisms). Streptococcus salivariussubsp. thermophilus grows at a faster rate right
after inoculation, and over the first 2 hours of incubation it produces lactic acid, carbon dioxide,
and formic acid which in turn causes Lactobacillus delbrueckiisubsp. bulgaricus to grow at a
faster rate. The initial drop in pH to 5 is brought about by Streptococcus salivariussubsp.
thermophilus, the growth of which is decreased by the high concentration of lactic acid.
Lactobacillus d. subsp. bulgaricus brings about the last reduction in pH to 4.6, and produces
peptides and amino acids for use by S. thermophiles. After four hours, the equilibrium between
the two bacteria will be reached, and fermentation is complete.

Packing, sealing and storage

Yorghurt at JESA farm Diary is packed in either cups or pouches can be used. For cups
aluminium foils are used for sealing the tops of the cups and for pouches,

The package machine completely seals the package film. The packages aare then coded by a
coding machine which prints on the details i.e

 Dates of manufacture
 Expiry
 Batch number
 Time of production.

Note; the batch number is the number of the day in the year

During the production process, the quality controller on line is responsible of picking samples (3
of them) every after an hour from the conveyor and the samples are distributed in different
places as below.

One sample is taken to the quality control lab for analysis. The parameters checked for include
weight, pH, Organo leptic test, viscocity, taste, color, mouth feel, Aroma and texture.

The remaining two samples are taken to the cold room where one is for retention and the other
for microbiology analysis.

Yoghurt dispatch.
After a period of 2 days (this means that the results from microbiology are ready), red or green
stickers are attached onto the crates. Red sticker implies that the product is on hold possibly due
to some quality deviations and implies that more investigation is still being undertaken while the
Green sticker implies that the product is free to be loaded and taken to the market for
consumption.

CREAM AND BUTTER PRODUCTION

The fat from the raw milk is first removed by skimming. Skimming removes all the fat and semi
skimming removes some of the fat. Cream is of two types i.e

Fresh cream (packed in jerry cans). This has a batter fat of about 38-40%

Butter cream is the one used for making butter. It has a batter fat of >40%

For butter,

Cream is removed from the cream tank at a temperature of about 55-60oC. it is then pasteurized
at a temperature of 95oC using a cream pasteurizer. The outlet temperatures for butter cream is
20-25 oC.

The outlet temperature is around room temperature because cultures are added therefore, the
temperature should neither make them domant nor denature them.

It is then sent to the cream storage tanks still at the outlet temperature of 20-25 oC.

A sample is then picked and taken to the quality control lab to check for the ph and temperature.
The pH before pasteurization is around 6.66-6.8.

Cultures are then added to the batter. The cultures include CHN22 and Holdbug YMC,
FreshQ11, FreshQ09.

CHN 22 is added to help serve as a preservative and the rest help to ferment the cream.

After culturing, the argitator is turned on at its maximum speed for 5minutes for the culture to
mix very well in the cream.

Another sample is picked and taken to the QC lab to analyse the temperature and pH after
culturing. The cream is now left for about 8 hours before chilling it so that the cultures can do the
fermentation.

When the pH is around 5.2-5.6, the chilled water is now turned to lower the temperature . this is
because cream is churned while cold. It is ready for churning at a pH of 4.6-4.8 and when the
temperature is below 100 oC. The system is now connected and cream is taken to the churner.
During churning, butter is observed to separate from the butter milk. The time taken for the
butter to form depends on:

 The temperature of the cream

 The thickness
 The volume in the churner i.e it should be half way the churner

After formation of butter milk and butter, the butter milk is poured off through the outlet.

Washing of the butter is then done using water at a temperature below 10 oC. washing is done in
order to remove the butter milk and this is done twice or thrice until when the washing water is
clean..

After washing, drying is done by lowering the speed of the churner to about 25% the maximum
speed.

For salted butter, (4kg of salt in 20litres of water) is added after drying the butter

A sample is then picked for moisture content analysis. The acceptable range for the moisture
content is (0-16%).

The butter is then packed in different packaging materials.

Note: The churn is not made full of cream because cream increases in volume during churning
therefore there should be room for expansion and separation of the butter milk.

The churner rotates at 50% its maximum speed.

Shelf life

Unsalted butter takes 6months

Salted butter takes 8months.

Moisture content Analysis of Butter

Requirements: metallic can, source of heat i.e hot plate, pair of tongs, weighing scale.

Procedure.

The weight of the empty metallic can is measured and its weight is recorded as A grams

10g of the butter is weighed using the metallic can. The weight of the metallic can and the butter
sample is recorded as B grams.

The sample is then heated until it just turns coffee brown. At this point, All the moisture is
expected to have evaporated. Using a pair of tongs, the sample is carried from the heat source
and left to cool to room temperature. The weight of the can and the butter sample is now
measured and recorded C grams.

( B−A )−(C− A)
The moisture content is then calculated from: Moisture content = ×100
B−A

For fresh cream

The batter fat range for fresh cream is 38-40%. The cream is pasteurized at a temperature of 95
o
C and the outlet temperatures are <10 oC.

After pasteurization, a sample is taken to the QC lab for analysis. The cream is then packed in
jerrycans.

The shelf life of fresh cream is 15days

Note: We don’t add cultures to fresh cream because fermentation is not required.

The charts below show flow diagrams for butter and cream respectively

CRATE WASHING
Crate washing is the process of cleaning the already used crates by the whole sale suppliers to
carry products from the industry.

This is done in order to ensure safe their safe reuse. Crate washing is also one of the daily
activities done at Jesa Farm Diary.

Crates are mostly used to carry pouch products i.e (full cream milk) and also used during the
storing of the pouch yoghurt in the cold rooms.

Averagely, around 13000 crates are washed every day. Basically the number of crates washed
everyday depends on the amount dispatched

Process of washing

On returning the crates to the industry, they are counted and then offloaded. They are counted to
comfirm there numbers as at dispatch.

Dirt that comes with the crate for example pouches, polyethene etc are removed from the crate.
After doing that, the crate is put into the crate washing machine.

Chemicals used for washing.

 P3Z (powdered chemical).

 Liquid soap.
 Lastex
 MIP Gluco
 Acid (Nitric Acid 68%)

Acid and Lastex are used for CIP of the machine. The purpose of Lastex is to remove the
remaining dirt in the machine.
During CIP, The machine takes one hour to do Acid wash and then Lastex is added. CIP
of the machine is done once a week.

MIP Gluco. This is a highly alkaline detergent especially formulated for automatic
washing of tanks.
This chemical removes fats, Grease proteins and other organic soils that are present in the
crates.
P3Z and Liquid soap are used for foam formation. This chemical also helps to chess away
flies.

Amounts required for one tank in the cleaning machine

 Chemical Amount required
MP3Z 1kg
Liquid soap 1 litre
Lastex 5kg
MIP Gluco 0.5kg
Acid (Nitric 68%) 25 litres
The machine consists of two tanks, one tank is for mixing chemicals and another tank is
for storing water to rinsing
The machine consists of nozzles which help to exit chemicals for cleaning and water for
rinsing using a very high pressure of about 8bars
Crates move automatically by help of a chain from the entrance to the exit of the
machine.
Steam from the boiler is used to heat the water. The desired temperature is around
34.3oC.

FULL CREAM MILK PRODUCTION

Full cream milk is fresh milk being packed in pouches with a shelf life of 6days.

Full cream dispatch is done on a daily basis and its dispatched the day it is manufactured. This is
due to its short shelf life.

Averagely, about 60000litres are packed everyday. Full cream milk is pasteurized milk and has
a butter fat of about 3.6%.

Mechanism of Packing

Full cream milk is packed in pouches using pouch machines.

The pouch machine consists of an upper jaw for vertical sealing and its at temperatures of about
16oC. The lower jaw does horizontal sealing and it’s at a temperature of about 24oC. The sealing
temperatures determine the firmness of the film.

The coding of the pouches is done using a dent.

If the temperatures are too high, they will weaken the packaging material and if the the
temperatures are lower, the sealing will not be effective

If the packing is not effective, the following are done;

 Another teflone is added

 The sealing temperatures are adjusted (increased or reduced)
  Another cutting element can be added.


Packing films

Films are used the ones from which pouches are made. Each full cream film packs around
2000litres of milk for each packing head.

Averagely, the weight is around 21kg of film, It can also be of 18kg, 17kg. If the film is too big,
the machine may fail to work.

Packing speed

The speed at machine at which the machine does its filling and packing process can be increased.
Different machines have different milk flow rates.

Averagely, the flow rate (speed) is around 3000litres per hour. A very high speed is undesirable
because

 vertical and horizontal sealing will not be done effectively.

 It will be hard to spot out leakers if the speed is too high.
 It leads into addition of excess air in the pouches which leads to bulged pouches.

After packing by the machine, full cream milk is put into crates. Either each crate carries
20 pieces of 500g pouches or 10 pieces of 1000g pouches. The milk is then taken to the
cold room preparing it for dispatch.
For leaking milk, rework is done before taking it to the cold room. Rework is done by
cutting the pouches, pouring the milk into the cans and taking back the milk to the
pasteurizer.
CIP of the filling machine is done every morning (long CIP) and deep CIP is done once a
week (thursday).
After CIP, ethanol 75% concentration is spread onto the pouch filling machines

DIARY HYGIENE
Milk is a perishable food product and easily falls prey to microbial contamination & increased
pH levels. This causes dairy products to diminish in quality and taste if proper hygiene measures
are not taken in manufacturing and storage conditions..

The contamination of dairy products can occur via various sources such as unhygienic
production & storage processes, handlers and equipment, environment, and packaging materials.
To avert the risks associated with poor standards of food safety prevalent in the diary industry, it
has become imperative for dairy farms and production units to stay compliant with GMP, GHP
and HACCP guidelines.

Maintaining good hygiene is crucial for the dairy industry to:

 Minimise or prevent contamination caused due to entry of pathogens and bacteria from
unhygienic milking procedures, equipment, milk contact surfaces, handlers, storage or
packaging conditions
 Ensure highest standards of food safety and improved compliance with regulatory
practices defined for the dairy industry
 Provide only highest quality and safe dairy products for end consumers

Understanding how to handle cleaning chemicals safely is also a point of interest. Surfaces that
are in contact with the food are cleaned first and followed by others.

Personal hygiene

 Thoroughly washing of hands using a high-quality disinfectant or hand-care product

before and after leaving the milk processing or production unit. Every time the hands
become soiled, they should be cleaned properly before getting back to the work area.
Finger nails should be cut short and clean.
 Performed hand soaps or lotions should not be used. Hands must be properly sanitised for
critical production areas.
 Any cut or open sore must be reported to the medical centre and covered by a band-aid
type coloured dressing
  Implement use of hygienic and sterilised clothing in dairy plant to prevent product
contamination. The workwear should not be worn when away from the production
facility or into the toilet, smoking room or canteen. Proper design of hygiene clothing is
essential to prevent the skin from coming into contact with the products.
 Wearing hand gloves is mandatory when handling or packaging the dairy products. Feet
should be properly covered with high-quality, disposable shoe caps.
 Dairy plants should also give utmost importance to effective workwear laundry. State-of-
the-art laundry facility and compliance with highest standards of hygiene is vital for safe,
sanitized and reusable clothing

The surfaces cleaned include

o Food contact surfaces i.e.

 Equipment surfaces
 Tables and preparation areas
 Conveyors
 Utensils
 Packaging material
• Outside of the equipment
• Environment; i.e.
o Floors
o Drains
o Walls

TYPES OF SOILS FOUND IN DAIRY PLANTS

• Carbohydrates.

Milk carbohydrates are primarily lactose with minor amounts of other sugars. Sugars typically
dissolve in water and can be removed with warm water. Presence of carbohydrate soils on the
equipment can cause contamination and hence spoilage.
• Proteins.

reaction. Milk proteins consist of casein and serum (whey proteins). They may or may not be
soluble in water. Typically they are removed from the surfaces by use of caustic soda.

• Minerals.

These consist of calcium, phosphorous, magnesium with trace amounts of other minerals. These
are used using acid solutions. Milk stone is a whitish or yellowish build up of the mineral residue
on the surface.

• Microorganisms.

In a dairy plant, they can originate from raw milk, air, water, palates, boxes, shoes, personnel and
other vectors. Microorganisms can be washed away from the surfaces during routine cleaning but
since they are always present in the environment, milk contact surfaces should be sanitized prior
to use. The main reason for sanitizing equipment is to reduce the microbial load on the surfaces
prior to use.

Biofilms

When bacteria get lodged in crevices, They lead into formation of a biofilm. They form if they
cannot be washed away. Biofilms form by attaching to and multiplication of the bacteria on the
surfaces. They form large masses that become encased in soils which protect them from
cleaning and sanitizing chemicals.

When the products move across the equipment containing biofilms, they break off causing a
high sporadic microbial count in the milk products. These counts are the ones that cause
spoilage.

Fat.
When caustic soda is added to fat, the chemical bond of the fat is broken down and the fatty
acids and glycerol are released from each other. This reaction is also known as saponification

Milk fat mainly consists of many fatty acids arranged in triglyceride structure that gives it a
broad melting range. Milk fat is not fully melted until 40⁰C. Alkaline solutions are used to
saponify the fat and remove it from the surfaces. If cold water is used, the fat then smears rather
than being removed. This can result in a layer of sticky fat inside the system that serves as
anchor points for bacteria to form biofilms

UTILITIES DEPARTMENT

Utilities are inputs requires to perfume a given production. They include:

 Fuel
 Water
 Electricity
 Compressed air
 Chilled water
 Nitrogen gas
 Hydrogen gas
 Treatment of wastes
 Steam
 Water treatment

STEAM PRODUCTION
Steam is produced by a boiler in the industry. It is at a temperature of about 200oC. It is
one of the utilities that are required to be provided in the industry.
Uses of steam
It is used during CIP
It is used during pasteurization
 Steam is also used during sterilization etc

Note Steam is supplied at a very high temperature but its temperature is regulated during
use.

OPERATION OF A BOILER

Points to note

 A boiler intakes soft water in order to produce steam.

 Boilers use diesel as fuel and some use liquefied Petroleum Gas (LPG).

Process of softening water for use in the boiler

Water is passed through the sand filter which help filter off the sand particles and also reduce the
turbidity.

From the sand filter, water is then passed through the carbon filter. This helps to filter off the
carbon and chlorine from the water. This is because chlorine may lead to formation of scales

Nitites is also another example of scaling chemicals.

The water is passed through another sand filter plus carbon.

It is then passed through a water softener. The water softener contains a cation called sodium
cation. These exchange resin to remove magnesium and calcium ions. Hard water is undesirable
because it causes foaming and scaling. Form disturbs the purity of the steam.

Sodium chloride (common salt ) is used to regenerate the resins to remove the ions that bind the
resins.

Note:

 About 2-5mg/litre of hardness is required in the boiler.

 The inlet pressure of the water to the filters is 8bars
 The filters are covered with a material that resists scaling. This is called Epoxy painting.
 An Epoxy paint is one that contains a material which prevents rusting.
 The treated water from the filters is at room temperature and is taken to the boiler feed tank.
In the feed tank, both the boiler anti scalant and the oxygen and carbondioxide scavenger are
dozed in through the chemical dozing pumps.

The anti scalant has a filming element which is an oxide. Its added to water to create a
hydroxide which is a film that coats the pipe to protect it from any corrosion attack. Some
caustic is added to the anti scalant in order to boost the pH. The desired pH range of the feed
water is 8.5-9.5. Boiler discaling is done every after a year.

The oxygen and carbondioxide scavenger helps remove these gases. This is because these
gases have a pitting corrosion (they dig holes) therefore they will destroy the boiler. The
oxygen level should be reduced to 0.005ppm by adding the oxygen scavenger and steam.

The boiler feed pump is hot because steam and condensate are added after circulating in the
system during the production processes. This also increases the efficiency of the boiler.

Cold water also enters the feed tank with gases. The increased temperature there also helps
to remove those gases i.e oxygen, carbondioxide. This is because they are undesirable since
they cause pitting corrosion.

From the Boiler feed tank, to the Boiler where the steam is formed.

Process of steam formation in the boiler.

The air vent is first adjusted before the start in order to remove the gases from the boiler.

The fuel is stored in the tank and from there, its pumped to the combustion chamber. Once it
reaches the combustion chamber, the fuel burns and it transfers the heat to the heat exchanger
which then heats the water forming steam. The pH range of the water in the boiler is 9.5-10.5

Fuel flow meters are used to monitor the amount of fuel operated.

As steam leaves the boiler, a steam separator is used to separate steam from the condesate. The
condensate that escapes this point is removed using a steam trap.

Note
  water to be turned into steam in the boiler exists on surfaces of tubes.
 The burning is ignited by an electric spark.
 A pump is used to create a mist flow of fuel in the fire tube.

A pressure switch monitors the working pressure of the boiler (10bars). This monitors the
automatic re-ignition of the boiler. Once the pressure set up in the boiler becomes less,
the boiler re-ignites. On ignition, the pressure increases and once it reaches the maximum
value it stops burning.

Some safety valves on a boiler

Blow down valve: This valve is used to control the total dissolved solid that settles at the
bottom. Less than 500ppm solids are required in the boiler.
Safety valve: it is used to control the excess pressure that may be setup in the fire tube.
It’s a safety mechanism to protect the boiler.
Fusable plug: it’s a safety valve that controls the boiler from explosion and damage due
to the feed water pump failure. If the water in the boiler is below the required range, the
boiler may blow and the pipes may fuse.
Feed check non return valve: This valve is used to prevent the back flow of steam to the
return line.

EFFLUENT TREATMENT PLANT

An effluent treatment plant is a plant used for treatment waste water.

At Jesa, a biological plant is used. This means that microorganisms (bacteria) are the ones used
to treat the water. This plant treats on brown water.

This water basically treats waste water from CIP. This is because its composed of chemicals that
may be of harm to the environment. Water that is not composed of chemicals is just allowed to
move and go to the wetlands.
Only a daily basis, about 150000 to 300000litres of waste water are treated. The overall ETP
capacity is 450000litres.

Transportation of waste water from the industry to the ETP

Waste water to be treated is well plumbed and given a single outlet from the industry. (the old
and new plant). They one from the old plant and the one from the new plant are joined to one
pipe that is even bigger and thicker.

The pipes carrying the waste water are put underground and inspection points (man holes) are
put along the path in order to make the inspection simpler. The pipes are big and thick in order to
allow carrying of large amounts of water without bursting. No pumps are used to move the water
to the plant, It just moves by its self

The process of treatment.

On reaching the plant, the waste water goes to the rotor stainer. This helps screen off the
remaining debris. This is done because debris is undesirable during the treatment process and no
debris can escape this point. The debris is collected and taken to the waste area. An overflow line
is used to help take out the water incase he rotor stainer is full.

From the rotor stainer, waste water is taken to the industrial feeding tank or collection tank. This
is a tank that reserves the water for some little time after screening, it is covered to prevent
another debris from falling into the water. This collection tank also helps to remove fats since it
floats on top, this is because fat is less dense than water.

A submissible pump is used to push the water from the feeding tank to the equalizer tank. This
pump works according to the float switches (level sensors) which provide information about the
amount of waste water in the equalizer tank.

The equalizer/buffer/storange tanks keeps the waste water so that the sequence batch reactor is
not interrupted. Apart from that, its does homogenization (equilizing) of the waste water for easy
balancing of the pH and uniform distribution of the water contents
During Homegenization, the flogets suck air from the atmosphere and a pump is used to push
the air which pushes the water around hence making it homogeneous. Online dozing in of
chemicals is done in order to make sure that the pH is in range. The required pH is 6.6-8.0. if it
goes higher than that, nitric acid will be dozed in to restore the range and if it is lower, sodium
hydroxide is used to bring to raise it to the range. The ratio of Acid to water in the dozing
chemicals is (15:35) and it’s the same for the one of caustic to water.

The homogenized waste water is then transferred to the sequence batch reactor tank . this is
termed as the charging/ feeding process. Actual water treatment takes place in these reactors.

Points considered before pouring the waste water into the reactors.

pH. Its should be 6.5-8.0. This is because this range will provide optimum growth for the
microorganisms that are going to do the treatment.

Temperature. It should be 25-35oC. this is because the microorganism will grow most in this
range.

Oxygen. This is because oxygen supports microbial growth (Aerobic microorganisms). Oxygen
will also help keep microorganisms active.

Note: Reactor tank has air diffusing systems which diffuse the air in the entire bottom of the
water.

The four major stages of a Reactor

 Charging/ feeding stage. It takes 5hours.

 Aeration stage (feeding oxygen). It takes 20hours
 Settlement or decantation stage. It takes 2.5 hours
 Discharge stage. It also takes 2.5 hours

Charging is the process of feeding the waste water in the reactor tank.

Aeration. Is the process of circulating oxygen in the reactor tank.

Settlement or decantation. This is a process by which the sludge settles at the bottom of the tank
and treated water at the top.

Discharge. This is a process by which clean water and some little slugde is exit from the reactor
tank. The sludge exit is little because its still needed inside the tank since it contains
microorganisms that do the cleaning.

SLUGDE TREATMENT

The little sludge that is exit is treated as follows.

 Chemicals are dozed into the sludge tank for it to settle.

 It is then pushed into the sludge press machine. This machine helps extract the remaining
water in the sludge.
 It is then digged out and dried. The sludge pieces can be used as fertilizers.