RWANDA INSTITUTE FOR CONSERVATION AGRICULTURE

(RICA)
AGR 203 ENTERPRISE 2

REFLECTION: SUSTAINABILITY OF FOOD PROCESSING

SYSTEMS IN THE DAIRY PROCESSING PLANT

AUTHORS: GROUP C2- SECTION C

Names Telephone numbers ID Numbers

ARAHIRWA Ineza Kevin 0786765600 RC20220004
BENIMANA Joyeuse 0790875233 RC20220089
MUGABO Richard 0787735122 RC20220042
NIYIGENA Irahoza Evelyne 0790873773 RC20220054
RUTWAZA M. Mediatrice 0781104954 RC20220066 (Team leader)

Submitted to: Dr. NKUNDA Dominique Savio

Submission Date: March 19, 2024
Table of Content

1.INTRODUCTION...................................................................................................................... 1
2. WATER IN FOOD PROCESSING ......................................................................................... 1
2.1 Use of water in Food processing ...................................................................................................... 1
2.2 Strategies for the reduction of water consumption. ....................................................................... 2
3. GAP: GOOD AGRICULTURAL PRACTICES .................................................................... 3
3.1 GAP: the 4 pillars.............................................................................................................................. 3
3.2 Strategies to insure viability of raw materials supply(sustainability) .......................................... 4
3.3 Strategies to ensure environment viability. ..................................................................................... 4
3.4 Strategies to ensure social viability (post-harvest handling) ......................................................... 5
3.5 Strategies to ensure food safety(contamination) and quality (nutrition value): .......................... 6
4. HCCP: Hazard Analysis of Critical Control Points .............................................................. 6
4.2 Hazards analysis................................................................................................................................ 9
4.3. CCP determination using decision tree ....................................................................................... 10
5. ENERGY OPTIMIZATION IN FOOD PROCESSING ..................................................... 13
6. STRATEGIES FOR WATSE MANAGEMENT .................................................................. 13
7. STRATEGIES FOR GHG REDUCTION ............................................................................ 14
8. CONCLUSION AND RECOMMENDATION..................................................................... 14
9. REFERENCES........................................................................................................................ 15

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List of tables

Table 1: Hazard analysis on each step ........................................................................................ 9

Table 2: : CCP determination on each step .............................................................................. 10

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List of figures

Figure 1: Fermented milk flowchart .............................................................................................. 8

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1.INTRODUCTION
Sustainable food processing is all about finding new ways of meeting present needs without
compromising future viability, given constantly changing economic and environmental conditions
(Tiwari et al., 2013).
Food processors face numerous challenges from ever-changing economic, social, and
environmental conditions. With global inequalities increasing, ingredient costs climbing, and
global climate change becoming a major political issue, food producers must now address
environmental concerns, social responsibility and economic viability when shaping their food
processing techniques for the future (Sustainable Food Processing, 2013).
This is not just a corporate social responsibility issue, but relates directly to efficiency, cost-saving,
and profitability, and so the food industry must increasingly embrace sustainable food processing
in order to succeed.

1.2 Objectives

The objective of this reflection was to:

• To understand the concept of sustainable food processing system

• To identify and develop sustainable practices in the dairy industry.

2. WATER IN FOOD PROCESSING

2.1 Use of water in Food processing

Water is an essential resource in the food processing industry, particularly within dairy enterprises.
Its multifaceted usage ranges from cleaning facilities and equipment to facilitating various
processing steps like heating, cooling, and sterilization.

Below is some of the main use of water in dairy enterprises:

Water for Cleaning the Facility and Equipment: One of the primary uses of water in dairy
processing is for cleaning the facility and equipment. It is used to remove soil, residues, and
bacteria from surfaces, equipment, and other materials.

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Water for Heating: Water serves as a heat transfer medium in dairy processing, particularly for
heating various ingredients and products. Steam produced from water is commonly used for
pasteurization, sterilization, and heating during milk processing.

Water for Cooling: In contrast to heating, water is also essential for cooling dairy products and
equipment. After pasteurization or other heat treatment processes, dairy products need to be rapidly
cooled to inhibit bacterial growth and maintain product quality.

Water plays a multifaceted role in food processing within dairy enterprises, encompassing
cleaning, heating, cooling, and sterilization processes. Its efficient utilization is vital for ensuring
food safety, product quality, and regulatory compliance.

2.2 Strategies for the reduction of water consumption.

Sustainable water management practices are increasingly important to minimize water

consumption, energy usage, and environmental impact in dairy processing operations.

Below is some of the Strategies for the reduction of water consumption in dairy enterprises:

Recycling of Used Water: Recycling and reuse of water is a highly effective strategy for reducing
overall water consumption in dairy processing. For example, water used for cooling purposes can
be collected, treated if necessary, and reused in subsequent cooling cycles.

Water Treatment for Cleaning: Water used in cleaning processes within dairy facilities often
contains detergents, sanitizers, and organic residues. Implementing water treatment systems, such
as filtration, sedimentation, and biological treatment, can help remove contaminants and improve
the quality of water used in cleaning operations.

Efficient Water Use: Optimizing water use through efficient practices and technologies is
essential for reducing consumption in dairy processing. This includes installing monitoring
systems. Additionally, implementing water conservation measures, such as capturing rainwater for
non-potable uses or employing water-efficient cleaning techniques, can further enhance water
efficiency and reduce overall consumption.

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Regular Maintenance to Prevent Leakages: Regular maintenance of water channels, pipelines,
and equipment is crucial for preventing leaks and minimizing water loss in dairy processing
facilities. Inspecting and repairing leaks promptly, conducting routine checks on valves, fittings,
and seals, and

3. GAP: GOOD AGRICULTURAL PRACTICES

Good Agricultural Practices (GAP) is a set of standards for the safe and sustainable production of
crops and livestock. It aims to help farm owners maximize yields and optimize business operations
while also minimizing production costs and environmental impacts (What Is Good Agricultural
Practices (GAP)? | Safety Culture, 2024).

3.1 GAP: the 4 pillars

GAP Pillar 1: Economic Viability Demonstrate
This pillar by providing sufficient evidence on the viability of farm operations such as management
reviews, annual reports, and financial plan.
GAP Pillar 2: Environmental Stability:
This means to sustain and enhance the natural resource base. The most recent Good Agricultural
Practices manual outlines critical requirements such as assessing the risk of causing environmental
harm on and off new sites, keeping records of the hazards assessed, and detailing the chemicals
used to sterilize soils and substrate.
GAP Pillar 3: Social Acceptability
This means to meet the cultural and social demands of society. An essential way of practicing this
principle is to protect the agricultural workers’ health from hazards brought on by the improper
use of chemicals and pesticides.
GAP Pillar 4: Food Safety and Quality
This means producing sufficient, safe, and nutritious food economically and efficiently. Control
should begin in the field to reduce the hazards of contamination. To act on this commitment,
evaluate the following elements of food safety and produce quality modules of GAP for fruits and
vegetables.

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3.2 Strategies to insure viability of raw materials supply(sustainability)

• Contract with big dairy enterprise: through long term agreement to ensure how much milk
is being procured, what the delivery schedule is expected to be hence relationship between
the supplier and milk processing plant.
• Use of fair pricing by setting milk price which strike the deal with supplier hence, boost
milk buying intentions and increases loyalty with the supplier to always ensure the stable
supply of milk.
• Setting quality control strategies of milk by starting where the milk is produced to ensure
that correct practices in production and handling are conducted, organoleptic tests by
identifying appearance, taste, smell of milk. This will help to assure the safety, freshness
of milk.
• Provision of trainings to the contracted farmers to help the farmers to improve their
practices such proper animal care, hygienic milk handling, feeding routine by the
introducing to the farmers the nutritious and appropriate quantity of feeds to the dairy cows
to produce high milk yield and reduce their shortage.

3.3 Strategies to ensure environment viability.

• Provision of trainings to the farmers by educating them to implement effective manure

management strategies by reduction of methane emission through improving feeds
efficiency and adopting anaerobic digestion systems for manure management to minimize
environmental impacts and destruction.
• Waste reduction and recycling this when some of the wastes will be reduces by reusing
them in other enterprise likely whey from milk in cheese making can be given to pigs rather
than exposing them and use appropriate quantity to reduce residuals in form of wastes.
Also recycling the one which are toxic to be used again.

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 • water conservation by only using desired quantity of water in case of any processing
activity rather than overuse of water by keeping taps open while cleaning. This will
minimize the wastage of water and maximize efficient use of water.
• Use of renewable energy resources which likely to be replenished to reduce emissions of
gases in atmosphere which can destroy environment through pollution of air. This would
keep the environment safe for production.

3.4 Strategies to ensure social viability (post-harvest handling)

• Training and Education of farmers: Provide training programs for farmers on proper
milking techniques, animal health practices, and hygiene protocols. This will help farmers
to provide milk with improved milk quality, leading to better post-harvest handling.

• Community Engagement activities: engaging with local communities in various

activities such as Umuganda (Community work) in building roads and other
infrastructures, this will facilitate efficient milk transport and reduce spoilage while
enhancing the welfare of the community.

• Conducting customer surveys: Through the surveys the enterprise gets valuable feedback
directly from customers. This will help us to understand the specific needs, preferences,
and expectations of customers to tailor the product to their needs. Also, seeking feedback
shows the commitment to transparency and responsiveness, which can enhance the
credibility of enterprise within community.

• Conducting fair labor practices: Through provision of decent wages, safe working
conditions, personal protective equipment, and access to healthcare for workers. This will
provide standard working conditions and enhance a positive work environment fostering
the long-term sustainability of the dairy processing enterprise.

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3.5 Strategies to ensure food safety(contamination) and quality (nutrition value):

• Hazard Analysis and Critical Control Points (HACCP) System: Through the
implementation of a HACCP system can help to identify and control hazards in the whole
processing system. This helps to prevent contamination and ensures food safety.

• Enhance the follow up of the whole chain (Traceability Systems): Establish systems to
track the origin of dairy products and ingredients from the farm to final product. This allows
identification of contaminated products and enhances consumers health.

4. HCCP: Hazard Analysis of Critical Control Points

Hazard analysis critical control points (HACCP) is an important part of food safety management.
It is a globally recognized, systematic and science-based approach to food safety that addresses
biological, chemical, and physical hazards throughout the food chain from primary production to
final consumption. The HACCP approach focuses on control measures for significant hazards
rather than relying only on end-product inspection and testing (Branch, 2024).

The effectiveness of HACCP is rooted in its seven principles, which provide a structured approach
to food safety management.
• Conduct a Hazard Analysis: This first principle involves identifying potential hazards
that could occur in the food production process and documenting them. It is a preventive
measure that anticipates problems before they arise.

• Identify the Critical Control Points (CCPs): CCPs are selected based on the hazard
analysis where control is critical to prevent or reduce the identified food safety hazards to
acceptable levels.

• Determine the Critical Limits (CLs): Each CCP must have enforceable measurable limits
set to ascertain when a CCP is under control or when there has been a deviation that needs
correction.

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• Establish Critical Control Monitoring Requirements: Monitoring procedures must be
established for each CCP to ensure compliance with the CLs. This can include
measurements or observations that provide evidence as to whether the process is in control.

• Establish Corrective Actions: When monitoring indicates a deviation from an established

critical limit, corrective actions must be taken. These are intended to regain control of the
process and ensure no unsafe product is released.

• Establish HACCP System Verification Procedures: Verification activities confirm that

the HACCP system is working effectively. This may involve reviewing CCP records,
testing the environment, or conducting product tests.

• Establish Record-Keeping Procedures: Accurate and detailed records are essential for
verification and provide documentation that the HACCP system is being managed
correctly.

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4.1 Processing flowchart of Fermented milk

Raw milk

Pasteurization

Pasteurized milk
Hold for 3 min.
Chill up to 30℃

Cooled milk
mesophilic starter culture
Inoculation

Cultured milk

Stirring for 5min

Fermented milk

Incubation for 17hrs(22-25℃)

Fermented milk

Stirring
Breaking the coagulum

Homogenous milk
Jerrycans
Packing
Labels Storage at 4℃

Packaged fermented Milk.

Figure 1: Fermented milk flowchart

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 4.2 Hazards analysis

Table 1: Hazard analysis on each step

Steps Microbiological Chemical hazards Physical hazards

hazards
Reception of raw milk Bacteria such as Antibiotics, pesticides, dirt, dust, insects, and
Salmonella, cleaning agents, residues foreign objects
Escherichia coli from feed
Pasteurization of milk Survival of Clostridium cleaning agents, Broken glass, foreign
botulinum sanitizers particles, insects
Cooling milk Survival of some Chemical substances dirt, dust, insects, and
bacteria e.g.: from water used in foreign objects
salmonella, clostridium cooling e.g. cleaning
botulinum agents
Cultured milk clostridium botulinum Contaminated additives dirt, dust, insects, and
(Inoculation) may still proliferate, foreign objects
Introduction of harmful
macro-organism during
inoculation
Fermented milk Acidic growth may Contaminated additives dirt, dust, insects, and
inhibit bacteria growth foreign objects
Packaging Microorganism in the Oils or lubricants used Broken packaging
packaging materials on the packaging materials, paper labels
materials,

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4.3. CCP determination using decision tree.

Table 2: : CCP determination on each step

Steps Hazard Is the control Does control Could the Do subsequent

at this at this step contamination steps eliminate
particular step eliminate or with the or acceptably
necessary for reduce likely hazard reduce the
safety? occurrence of identified hazard?
the hazard to occur in excess
an acceptable of acceptable
level? levels?
Reception of Physical: Yes, control at Yes, proper Yes, if proper Pasteurization in
raw milk foreign this stage is inspection and measures are the following
particles like critical to testing can not taken, step will
grasses, hair, ensure that milk reduce the contamination eliminate or
small leaves. is safe for likelihood of could exceed reduce
Biological: further biological and acceptable biological
Pathogens processing chemical levels. hazards to an
Chemical: hazards. acceptable level.
antibiotics However
chemical
contaminants
might need
further control in
subsequent
steps.

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Pasteurization Physical: Yes, control is Yes, Unlikely for Proper handling
of milk Could include necessary to pasteurization biological and storage are
contaminations prevent significantly hazards due to necessary to
during physical and reduces the pasteurization, prevent
handling chemical likelihood of but possible for recontamination.
Biological: contamination biological chemical
hazards are after hazards. hazards if not
reduced. pasteurization. properly
Chemical: controlled.
could include
post-
pasteurization.

Cooling milk Physical: Yes, control is Cooling Yes, if cooling Proper handling
Contamination necessary to reduces the and storage and processing
from cooling prevent growth rate of conditions are in subsequent
particle like physical bacteria but not optimal, steps are
flies. contamination doesn't contamination necessary to
Biological: during cooling eliminate them could exceed maintain safety.
Slow growth of and storage. entirely. acceptable level
bacteria.

Cultured milk Physical: Yes, control is Proper Yes, if culturing Fermentation

Foreign necessary to sanitation and conditions are will further
particles prevent control of not optimal or reduce
within starter contamination culturing equipment is biological
culture. conditions can not properly hazards, but

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 Biological: during culturing reduce the cleaned, proper handling
Pathogens and handling. likelihood of contamination is necessary to
from contamination. could occur prevent
environment or recontamination.
starter culture.

Fermentation Physical: Yes, control is Fermentation Possible, if Proper storage is

of milk Particles from necessary to reduces the fermentation necessary to
the prevent likelihood of conditions are maintain safety.
surrounding physical biological not optimal or if
environment contamination hazards that there's
and flies. during could have contamination.
fermentation. remained in
the milk.
Homogeneous Physical: At Yes, control is Previous steps Possible if Proper
milk this stage there necessary to have reduced proper hygiene packaging and
could be house prevent the likelihood and sanitation storage are
flies, and other physical of biological practices are not necessary to
particles from contamination hazards. followed during maintain safety.
the during homogenization
surrounding homogenization and packaging.
environment. and packaging.

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5. ENERGY OPTIMIZATION IN FOOD PROCESSING
Energy is the most contributor to greenhouse gases. So, in avoiding such emissions, the industries
or processing facilities must adopt preventive measures to reduce greenhouse gas emissions by
using clean energy sources. Some of these measures which can be adopted are explained below:

• Using power saving machine: This involves using machines that are designed to save
power, choosing high technology appliances and devices that have energy-saving features
and also going for the equipment that operates efficiently and consumes less electricity.
• Using energy wisely and efficiently: This means to be mindful of energy consumption.
This applies when the machines and lighting systems are not in use. When they are not
working, they must be turned off. Another strategy for minimizing the usage of energy is to
consider using natural light during the day instead of relying solely on artificial lighting.
• Using renewable energy power source: This involves using other alternative sources of
energy such as solar or wind power. For our country, wind source of energy is not common
as solar energy. This has already been adopted by RICA by using mainly electricity coming
from solar panels.
• Following the right procedures to avoid excessive use of unnecessary energy: On this
strategy, it involves following the protocols of processing, by using the exact required
amount of energy for example in the case of heating. Some of the processing activities in
processing involves heating on a gas stove which is a non -renewable energy. Using
unnecessary heating time will lead to overutilization of unnecessary energy.

6. STRATEGIES FOR WATSE MANAGEMENT

Appropriate waste disposal is a crucial element for any processing enterprise including RICA dairy
processing plant. Having inappropriate waste disposal will affect not only humans but also the
entire environment. The waste can be managed or controlled in the following explained ways:

• Appropriate disposal: By this, degradable and non-degradable waste must be separated.

Degradable wastes are those that can be decomposed and contribute to the formation of
organic matter for the soils. Non-degradable wastes are those which are not decomposable.

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 • Composting and recycling: Implement composting programs to handle organic
waste/degradable wastes, such as dairy by-products like whey. For non-degradable wastes
such as plastics and some of the packaging materials can be reused again.
• Waste treatment: For wastewater resulting from cleaning activities, they must be collected
in one location for further treatment to be reused again after somedays.

7. STRATEGIES FOR GHG REDUCTION

• Using GHG sequestering machines: These machines attract carbon dioxide (CO2)
emitted in the atmosphere and converts them into less harmful carbon monoxide (CO).
CO2 is the main contributor gas among the greenhouse gases.
• Using renewable energy resource: Renewable energy is the source of energy which gets
replenished. They are the clean source of energy as they emit less harmful gases in the
atmosphere. Adopting the use of renewable source of energy can reduce the emission of
those greenhouse gases. Examples of renewable source of energy used in Rwanda mainly
is solar energy.
• Planting trees around the facility: Trees will play an important role in attracting the
carbon dioxide found in the atmosphere and use it in its natural synthesis of food
(photosynthesis). As we plant more trees, more carbon dioxide will be trapped from the
atmosphere, hence reducing the greenhouse gas emissions.

8. CONCLUSION AND RECOMMENDATION

In conclusion, achieving sustainability in food processing systems, particularly in dairy processing
plant requires balancing environmental, economic, and social considerations for long-term
viability. Achieving sustainability involves minimizing environmental impact through efficient
resource utilization and waste management, optimizing economic efficiency through cost-effective
production methods and investment in innovative technologies. By embracing sustainable
practices, dairy processing plants can contribute to environmental preservation, economic
prosperity, and social well-being.

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9. REFERENCES

Tiwari, D., Norton, D., & Holden, P. (2013). Sustainable Food Processing. Wiley-Blackwell.
https://www.wiley.com/en-gb/Sustainable+Food+Processing-p-9781118634370

What is Good Agricultural Practices (GAP)? | Safety Culture. (2024, January 23). Safety Culture.
https://safetyculture.com/topics/good-agricultural-practices/#What-are-the-4-Pillars-of-Good-
Agricultural-Practices

Branch, E. (2024, March 9). Hazard Analysis and Critical Control Points (HACCP): an in-depth
study. IIENSTITU. https://www.iienstitu.com/en/blog/hazard-analysis-and-critical-control-
points-haccp

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