Special : Milk & Milk

Products
 PART-I
INTRODUCTION TO FOOD SAFETY
• Food safety & food safety hazards
• Quality Assurance
Quality
Quality is a measure of the degree of excellence of degree of acceptability by
the consumer. It also covers the safety and value for money.
Important components of food quality
1. Food safety
I. Food borne illness
II. Food hazards
III. Food Safety Management System Certification (FSMS)
IV. The Food Safety and Standards Acts, 2006
V. Recent Concerns of Food safety
2. Nutritional Value
3. Sensory Characteristics
Food Safety Hazard means biological, chemical or physical agent in
food or condition of food with the potential to cause an adverse
health effect. There are majorly four type of hazard.
Source of contamination throughout food chain
Bacterial Growth
Exercise
• What do you understand by hazards and how do you handle it at your end ? Experience sharing in
groups
• What is the importance of maintaining cold chain in food safety ? What kind of issues have you
resolved due to cold chain failure ? How did you manage it ?
• You can also share relvant case studies or videos here if available.

• 20-30 mts
 PART II
 
• LOCATION, LAYOUT & FACILITIES
• CLASSIFICASTION OF DAIRY PLANT
• PLANING CONSIDERATONS FOR DAIRY PLANT AND SITE LOCATION
• LAYOUT & DESIGN OF DAIRY ESTABLISHMENT PREMISES
• EFFLUENT TREATMENT PLANT
 
CLASSIFICASTION OF DAIRY PLANT
1. Liquid milk Processing Plant
 In such Dairy plant, raw milk received at dock is chilled, processed (Pasteurized) and packed for
sale.
 This type of plant has low value addition but the liquidity of money is very high.
 The liquidity is better because payment for raw milk is done after 7 to 10 days, whereas realization
is either in advance or on the same day.
2. Product manufacturing Dairy Plants:
 Raw milk is transformed into value added milk and milk products
 It’s advantage is conversion of perishable milk into long shelf life products.
 Long shelf life products are also suitable for distinct market.
3. Composite Dairy Plant:
• Dairy plants do have facilities for processing and packaging of liquid milk and milk products.
• In this way, Dairy plant can be benefited for high liquidity along with the advantage of increased
shelf life and value addition.
• Such milk plants are more viable and sustainable.
SITE LOCATION
The criterion, which has foremost operational important is
 minimum cost for procurement, production and
distribution.
 Other essential factors which should favour the location
include topography, shape and size of site,
 Availability of water, power and fuel and, climatic
conditions.
 Rail and road connectivity
 Effluent and solid waste disposal.
Vegetation Stagnant water near
However due to increased pollution and industrialization, all growth near the surroundings
sites are not permitted for industrial work. premises
Process & Storage Equipment
Characteristics of food contact surfaces of equipment:
 Made up of non-corrosive / rust free material
 Smooth, free from any grooves
 Easy to clean and maintain
 Non-toxic and non-reactive
 Food grade quality

Generally food grade stainless steel 304 or 316L

is preferred.
Design of Facilities
• Dairy plant has to be provided with
required facilities for water supply,
drainage/waste disposal, cleaning
system, personal hygiene, toilets,
humidity, air and temperature
control, lighting and storage of
various materials.

Electrical panel and board should be Proper slope for

covered drainage.
Water Quality for Dairy processes
• The specific method adopted for conventional treatment such as flocculation /
coagulation, filtration and disinfection, lime soda softening process, electro-
dialysis, demineralization and reverse osmosis depending upon product
quality requirement.
• The specific method adopted for conventional treatment such as flocculation /
coagulation, filtration and disinfection, lime soda softening process, electro-
dialysis, demineralization and reverse osmosis depending upon product
quality requirement.
Treated waterParameter
quality parameters forQuality
use in Dairy processes:
TDS < 50.0 mg/ltr
pH 6.5 – 7
Chloride < 30.0 mg/ltr
Turbidity < 1 NTU
Total Hardness < 8 mg/ltr
Exercise
• Que 1. What are the factors to be considered while selecting good site for setting up a dairy
plant ? What kind of issues have you observed and resolved at your current site ?

• Que 2. What is importance of designing for your dairy plant ? Identify key factors responsible for
food safety failures while designing a dairy plant ? Group discussions based on your
current experience.
• Que 3. How should we develop separate sections in a dairy plant ranging from highly vulnerable to
safest in context of food safety ? Group exercise and presentation.

• 30-45 minutes
 Part III

Dairy Processes and Equipments

PART III
MILK PROCESSING & PACKAGING
• Clean Milk Production at Farm and DCS level  
• Raw milk Reception at Dairy Plant
• Chilling& Storage of raw milk
• Processing
• Clarification
• Bactofugation
• Cream Separation
• Standardization
• Homogenization
• Pasteurization
• Packaging (Sachet)
• Different types of Milk & Milk Products  
• Packaging requirements for Milk and Milk Products
Clean Milk Production
Milk
Milk is considered to be the mammary secretion of a healthy animal. Hence
animal health is an important aspect in the production of clean milk. Good
hygiene and sanitation practices would keep it free from bacterial
contamination.
Essential steps for Clean Milk Production At Farm and DCS Level
 Give sufficient quantity of feed and drinking water to cattle prior to milking.
 Remove accumulated cow dung.
 Cattle shall be bathed and if bath is not possible dry cleaning by broom / duster
should be done.
 Maintain the cattle clean and healthy.
Clean milk Production

 In case animal is under treatment, discard the milk during the withdrawal
period of the treatment. Do not bring the milk to DCS (Dairy Cooperative
Society) / MCC (Milk Collection Centre), if the cattle is suffering from any
disease.
 Clean the cattle shed floor either by washing with water or dry cleaning 10 –
15 minutes before milking.
 The floor should not be slippery. It should be firm and dry so as to provide a
proper foothold to the animal while rising or standing.
 Clean the udder and teats of the cattle by clean (potable) water and wipe
using a dry & clean cloth.
 Use separate vessel for washing of udder and teats & for milking.
Clean Milk Production Continue

 Teats should be cleaned after sucking, if cattle is letting down the milk by calf
sucking.
 Clean thoroughly the milk collection vessel preferably with detergent and hot
water etc. and keep it inverted to dry before milking.
 Milker should wash his/her hands with soap to make them clean and germ
free.
 Milker should wear clean clothes.
 Chewing and spitting with tobacco and smoking should be avoided during
milking.
 Milker should not be suffering from any respiratory ailment or contagious
disease.
Clean Milk Production Continue

 Milker should not have any open sores or cuts.

 Discard the initial milk from all the four teats to minimize the bacterial load.
 Flies, hay, husk, dry cow dung cake or other extraneous matter should not get into the milking
vessel.
 After milking rinsing of teats in a dis-infective solution (with water, iodophor etc.) shall be done to
avoid post milking infection.
 It is good to keep the animals standing for at least half an hour after milking. Feed may be
provided to encourage this.
 Avoid use of measures, tumbler etc. in the milking vessel for removing or to transfer milk from
milking pail.
Clarifier
The function of the clarifier is to remove undesirable
milk solids like dirt, dust, hay, manure, bacteria,
somatic cells and pulverized hair by the application
of centrifugal force.

Bacteria Removing Clarifier

The function of the Bacteria Removing Clarifier is to remove
bacterial spores present in milk by the application of
centrifugal force. 2-stage Bactofugation can remove 99.9%
bacterial spores and 90% bacteria from milk.
Cream Separator 
The cream separator is a centrifugal equipment that
sepa­rates milk into cream and skimmed milk.

Milk Standardization
 
The separated cream and skim milk are remixed in certain proportions to make
standardized milk as per further process/market requirement. Different types of
milk like Toned, Double toned, Standardized, Full cream etc. have different
standards of Fat & SNF as prescribed by the FSSAI.
 
Standardization of Milk for Fat:
1. This can be made by simple Person square method. Only Fat or SNF can be
standardized by this method.
 
2. Standardization of Milk for Fat & SNF: This can be made by Algebraic method.
 
3. On line milk standardization: This is achieved by using combination of online
Density-meter and Flowmeter instruments.
Auto-standardization u
Pasteurizer
• Pasteurization (LTLT/HTST) is a process that kills pathogens in
milk.
• This is achieved by heat­ing the milk in the pasteurizer to a
temperature of minimum 72° centigrade, holding it at that
temperature for 15 seconds and then rapidly cooling it below 5
degree centigrade.

Homogenizer
• Homogenization is the process of reducing the fat globule size below
2 microns so that they float sus­pended evenly throughout the entire
milk solution. Homogenizer is the equipment used for
Homogenization.  
• Homogenization is done in two stages. In first stage, the milk is
passed through small openings with applied pressure of 2500 PSI
followed by 500 PSI in 2nd stage to prevent fat globule clumps.
Crate washer
A typical crate washer consists of a washing section(s) and a
rinsing section. In these sections the nozzles that are mounted
on the spraying racks will produce the Mechanical Action of
the Temperature Controlled and Chemical Dosed water. Each
washing section has its own reservoir for re-use of the
washing water and for the rinsing section, fresh water will be
used. A transport chain or transport belt will be used to
transport the crates through the machine with a certain
(controllable) speed to meet the Washing Time for a certain
crate/pollution.

Advantages of High Pressure Jet cleaning:


Reduction in plant down time

Saves labour cost and space

Environment friendly as it saves water, reduces noise
pollution & air pollution as there is no generation of
gas, smoke and heat
• Safe to use: Effective cleaning without/less use of
hazardous chemicals with no damage to the
underlying surface
High Pressure Jet cleaning in Crate Washer
Different types of Milk& Milk Products
Exercise
• What kind of processes plays the most important part in Food safety ?
• How does Clean Milk production at farm level help in reducing the burden of Food safety at plant
level ? Group exercise and experience sharing with examples.
• What is the role of processes like clarification and bactofugation in creating food safety for
processing of value added products ?
• What all needs to be done to ensure food safety in batch processes for making Indian sweets or
value added products in small quantities ? Group exercise
• How does food safety requirements varies with change in product mix from liquid milk processing
to processing of fermented milk products and UHT products ? Group exercise.

• 30-45 minutes
 PART IV
CLEANING & SANITATION AND EQUIPMENT MAINTENANCE
 
CLEANING & SANITATION AND EQUIPMENT MAINTENANCE
 
• Cleaning & Sanitation
• Food Soils & their removal
• Cleaning-In-Place (CIP)
• Sanitation/Disinfection
• Checks for Cleaning Efficiency
• Hygiene station
• Equipment Maintenance
• Instrumentation in Dairy Sector
Cleaning & Sanitation
Milk is a perfect media for growth of micro-organisms at ambient
conditions and gets easily contaminated once it comes in
contact with un-cleaned equipment and vessels. It is,
therefore, essential to clean & sanitize the equipment in
which milk is held during processing. There are different
methods for cleaning:

• Manual
• Semi-automatic
• Automatic

Cleaning-In-Place (CIP)
CIP is the cleaning of Dairy plants without dismantling
equipment/pipes and without altering the production process
configuration.
Checking the efficiency of cleaning by
1. Swab test
2. Rinse test
Food Soils & their removal
Components Solubility Ease of Change on heating
on surface removal

Sugar Water & acid Easy Caramelization –

soluble more difficult to
clean
Fat Water in- Difficult Polymerization –
soluble, alkali more difficult to
soluble clean
Protein Water- Very Denaturation- much
insoluble, difficult more difficult to
alkali soluble, clean
slightly acid-
soluble
Mineral Variable Easy to Generally easy to
Salts water- difficult clean
solubility,
mostly acid-
soluble
Sanitation/Disinfection
Why is disinfection necessary?
 Cleaning may not be 100% effective.
 Microorganisms remain on surfaces after cleaning.
 Some of these organisms may be pathogens or
spoilage organisms.
 Disinfection with hot water 90 – 95°C for 5 minutes

The main disinfectant :

Effective sanitation depends on
 Concentration Aldehydes

 Temperature Alcohol

 Contact time Iodophor

 Degree of soiling Phenolics

 Water hardness Chlorine (Hypochlorite)
 pH
Equipment Maintenance
There are 3 types of maintenance:
1. Corrective/ Break-down maintenance
Corrective maintenance of equipment after equipment break down or malfunction and is often most
expensive. The worn out equipment part can damage other parts and lead to multiple damage and
increase repair/replacement costs. Machine downtime is highest and lead to production losses as
well.
2. Preventive maintenance
It is performed with the intent of avoiding failures, safety violations, unnecessary production losses,
and to conserve original materials of fabrication. The effectiveness of a preventive maintenance
schedule depends on the Root Cause Analysis. The history sheet maintained also helps in early
detection of problems and increased equipment life.
3. Predictive maintenance
This maintenance strategy uses sensors to monitor key parameters within a machine or system and
uses this data in conjunction with analysed historical trends to continuously evaluate the system
health and predict a breakdown before it happens e.g. on-line monitoring of bowl speed, motor
current, flow-rate etc. during operation of Clarifier / Cream separator / Bacteria removing clarifier.
Pasteurizer maintenance
Periodic inspection of Pasteurizer for leakages and opening of Pasteurizer once in 6 months.
Checking of rubber gaskets i.e. corner gasket, channel plate gasket and end plate gasket when the
Pasteurizer is opened every six months. In case leakages are observed before six months, it needs to
be checked immediately.
Checking of pin holes in PHE plates, block and tie-rod after every 10 years of interval.
Homogenizer maintenance

Homogenizing
head Quarterly Valve Seat
    Forcer
1
 
      Impact Ring
Homogenizer
 
2 Oil Changing After 5000 running hours
Exercise
• What is the importance of cleaning and sanitizing the dairy plant ? What is the difference between
the two ?
• How does you test whether the cleaning and sanitization done at your plant is sufficient and is
effective ?
• What are the hazards associated with uncontrolled cleaning and sanitizing at a dairy plant ? Group
discussions
• What are the emerging trends in availability of chemicals and sanitizers for dairy industry ?
Discussion

• 20-30 minutes
 PART-V
PERSONAL HYGIENE
PERSONAL HYGIENE
• Health status, Behavioural &
• Personal cleanliness of Plant operators &Visitors
• Safety Systems for Dairy industry
 Health Status
• Personnel known, or believed, to be suffering from, or to be a
carrier of a disease or illness likely to transmitted through food,
shall not be allowed to enter into any food handling area.  
• Any person affected, shall immediately report illness or symptoms
of illness to the management and medical examination of a food
handler shall be carried out apart from the periodic check-ups, if
clinically or epidemiologically indicated.
• Arrangements shall be made to get the food handlers / employees
of the establishment medically examined once in a year to ensure
that they are free from any infectious, contagious and other
communicable diseases.
• A record of these examinations signed by a registered medical
practitioner shall be maintained for inspection purpose. 
• In case of an epidemic, all workers are to be vaccinated irrespective
of the scheduled vaccination.
Behavioural & personal cleanliness
Continue
Visitors
• Generally visitors should be discouraged from going
inside the food handling areas.
• Proper care has to be taken to ensure that food safety
& hygiene is not getting compromised due to visitors in
the floor area.
• The Food Business shall ensure that visitors to its food
manufacturing, cooking, preparation, storage or
handling areas must wherever appropriate, wear
protective clothing, footwear and adhere to the other
personal hygiene provisions envisaged in this section.
SAFETY SYSTEMS FOR DAIRY
INDUSTRY 
Dairy industry involves several hazards. To handling these hazardous
environment following safety systems are very essential.
1. Fire fighting systems: i. Fire hydrant
ii. Fire Extinguishers for different types of
Fires- A, B, C or combination
iii. Fire Sand Buckets
iv. Sprinkler systems
2. Emergency alerting system: i. Smoke Detectors of optical and heat
sensing type
ii. Ammonia Detector 
3. Emergency Declaring systems i. Emergency Siren
ii. Manual Call Points
4. Emergency Indicating systems – Cold room bells
5. Escape routes
Exercise
• What are the possible threats in food safety if personal hygiene is not supervised and controlled
well ? Experience sharing
• Personal hygiene is a mindset and can not be taught ? Debate

• 20-30 minutes
 PART-VI
MILK & MILK PRODUCTS TRANSPORTATION, STORAGE &
DISTRIBUTION
Milk & Milk Products Transportation
• The vehicles used to transport milk and milk products must
be maintained in good condition and kept clean. 
• Ensure that as much as possible the required temperature
shall be maintained throughout the supply chain from the
place of procurement or sourcing till it reaches the end
consumer including chilling, transportation, storage etc. 
• Milk and milk products while in transport in packaged form
or in containers shall maintain the required temperature.
• Whenever frozen food / raw materials are being used /
handled / transported, proper care should be taken so that Road Milk Tanker
defrosted / thawed material are not stored back after
opening for future use.

Refrigerated vehicle for transportation of Dairy

products like Ice-cream, Butter, Cheese and Paneer
No space between wall and Proper stacking of raw material
stack may lead to unhygienic away from wall
conditions & pest infestation
Stock
Management
 PART-VIII
MILK & MILK PRODUCTS TESTING
MILK & MILK PRODUCTS TESTING
• Sampling
• Quality Testing Parameters
• Microbiological standards for Milk & Milk Products
• Safety Testing Parameters
Basic Milk Analysis
Quality Testing Parameters
Raw Milk
Milk when received from different chilling units & societies is
measured & sample is drawn for quality testing. A small bottle of
milk is also given by the centres along with the Chalan data to
compare the result of fat, SNF, acidity. This helps in determine
whether adulteration has taken place or not during transportation.
Following test are performed for raw milk:
• Titratable acidity
• Clot on boiling test
• Alcohol test
• Methylene Blue Reduction Test
• Fat
• SNF
Safety Parameters for CONTAMINANTS
 
It is provided under the conditions of
license as per FSSR licensing and
registration regulations that every FBO
shall ensure that his food product is tested
for relevant chemical and microbiological
contaminants through FSSAI notified /
NABL accredited or own laboratory at
least once in six months.
Exercise
• What is the role of robust milk and milk product testing in a dairy plant ? Discuss
• How could one validate that the results coming out from laboratory are correct ? Share how does
the results in your laboratory were challenged by a third party. Experience sharing
• Too much of quality testing leads to poor efficiency in a dairy plant ? Group exercise with real time
experience sharing
• Quality and Process are two mutually exclusive pillars of a dairy plant ? Debate

• 30-45 minutes
 PART-XI
PRODUCT INFORMATION & CONSUMER AWARENESS 
PRODUCT INFORMATION & CONSUMER AWARENESS 
• Labelling
• Manner of Declaration
• Specific Requirements/ Restrictions on manner of labelling
• Exemptions from labelling requirements
• Notice of addition, admixture or deficiency in food
 Labeling of Pre-packaged Foods

In addition to the General Labeling requirements, every

package of food shall carry the following information on the
label, namely –
Name of the food
List of ingredients in descending order
Nutritional information
Declaration regarding food additives Advance food safety
handbook/manual for food manufacturer’s, processor’s &
Packers 2, 2017
Labeling of Pre-packaged Foods contd/-

Name and complete address of manufacturer or

packer
Net content by weight or volume
Date of Manufacture / Packing
Lot / Code / Batch identification
Best Before Date
Instructions for use
Importer details and Country of origin for imported
products
All the contents provided on the label must be clear,
prominent, indelible and legible.
License number shall be displayed on the principal display
panel in the following format
Declaration regarding veg or non-veg

Fluid milk: — The caps of the milk bottles

/pouch/tetrapack shall clearly indicate the nature of the
milk contained in them. The indication may be either in
full or by abbreviation shown below:
(i) Buffalo milk may be denoted by the letter ‘B’.
(ii) Cow milk may be denoted by the letter ‘C’
(iii) Goat milk may be denoted by the letter ‘G’
(iv) Standardized milk may be denoted by the letter ‘S’
(v) Toned milk may be denoted by the letter ‘T’
(vi) Double toned milk may be denoted by the letter ‘DT’
(vii) Skimmed milk may be denoted by the letter ‘K’
(viii) Pasteurised milk may be denoted by the letter ‘P;
followed by the class of milk. For example
Pasteurised Buffalo milk shall bear the letters ‘PB ‘.
Exemptions from labelling requirements

 list of ingredients, Lot Number or Batch Number or Code Number, nutritional information and
instructions for use if package is not more than 100 cm2 but these information shall be given on
the wholesale packages or multi piece packages.
 The 'date of manufacture' or 'best before date' or 'expiry date‘ if less than 30 cm2 but these
information shall be given on the wholesale packages or multispecies packages.
 In case of liquid products marketed in bottles, if such bottle is intended to be reused for refilling,
the requirement of list of ingredients shall be exempted, but the nutritional information specified
in regulation.
Provided that in case of such glass bottles manufactured after March 19, 2009, the list of ingredients
and nutritional information shall be given on the bottle.
 In case of food with shelf-life of not more than seven days, the 'date of manufacture' may not be
required to be mentioned on the label of packaged food articles, but the 'use by date' shall be
mentioned on the label by the manufacturer or packer.
 In case of wholesale packages the particulars regarding list of ingredients. Date of manufacture/
packing, best before, expiry date labelling of irradiated food and, vegetarian logo/non vegetarian
logo, may not be specified.
Exercise
• Whose responsibility is to provide information given on label in your dairy plant ?
• Has the information provided been validated on contents or nutritional facts ?
• What is the importance of metrology in labeling ?
• How often the changing labeling requirements from the regulator are discussed in your plant ?
• Share your experience on some market complain over the labeling issue on your product and how
was it resolved ?

• General discussions 20-30 mts

 PART-XII
FOOD SAFETY MANAGEMENT SYSTEM PLAN
FOOD SAFETY MANAGEMENT SYSTEM PLAN
• Introduction
• Structure of the FSMS Program
• Flow chart
• FSMS Plan
• Conclusion
Introduction of FSMS
A Food Safety Management System (FSMS) is a network of interrelated elements that combine to
ensure that food does not cause adverse human health effects. These elements include programs,
plans, policies, procedures, practices, processes, goals, objectives, methods, controls, roles,
responsibilities, relationships, documents, records, and resources. The purpose of FSMS is to
ensure the manufacture, storage, distribution and sale of safe food.
However, under current Indian regulation defined by the FSS Act 2006, Food Safety Management
System (FSMS) means the adoption Good Manufacturing Practices, Good Hygienic Practices,
Hazard Analysis and Critical Control Point and such other practices as may be specified by
regulation, for the food business.
The Key elements of any FSMS are
 Good Practices/ PRPs
 Hazard Analysis /HACCP
 Management Element / System
 Statutory and regulatory requirements
 Communication
Structure of the FSMS Program:
Sample Flow chart for pasteurized milk
Sample FSMS Plan for Raw milk reception
Exercise
• Develop an FSMS plan for a 200000 lpd composite dairy plant processing pasteurized milk,
Fermented milk products like Curd, butter milk, Lassi, Panir, Sweetened flavored milk, butter and
ghee ? Take any assumption on product mix variant . Group exercise followed by presentation

• The presentation must cover all key elements related to FSMS with indicative responsibility.
• How will you make food handlers about this plan in your plant

• 60-90 minutes
 PART-XIII
HACCP (Hazard Analysis and Critical Control Point)
HACCP (Hazard Analysis and Critical Control Point)
• Introduction
• HACCP Principles
• Purpose & Importance of Hazard Analysis
• Hazard Analysis Process, Hazard Identification& Evaluation, Control Measures
• Flow Diagram of Liquid Milk & UHT Milk processing
Introduction
• Milk is highly perishable commodity and a nutritious food so there is high risk of hazard or food
poisoning. Hazard analysis is the process used by the HACCP team to determine which potential
hazards present a significant health risk to consumers. Only those hazards that pose significant risk
to the health of consumers should be included in the HACCP plan.
HACCP Principles
• PRINCIPLE 1: Conduct a hazard analysis.
• PRINCIPLE 2: Determine Critical Control Points (CCP)
• PRINCIPLE 3: Establish critical limit (s).
• PRINCIPLE 4: Establish a system to monitor control of the CCP.
• PRINCIPLE 5: Establish corrective action to be taken when monitoring indicates that a particular
CCP is not under control.
• PRINCIPLE 6: Establish procedures for verification to Confirm that HACCP system is working
effectively.
• PRINCIPLE 7: Establish documentation  concerning all procedures& records appropriate to
these principles and their application
Purpose of the Hazard Analysis
• The purpose of the hazard analysis is to develop a list of hazards which are of such significance
that they are reasonably likely to cause injury or illness if not effectively controlled.
• Successful application of HACCP principles 2-7 depends on a high-quality hazard analysis
Importance of Conducting a Thorough Hazard Analysis
• An improper hazard analysis may result in a HACCP plan that is not effective in protecting
consumers regardless of how well it is followed.
• Plant operations may be modified based on a thorough hazard analysis.
Hazard Analysis Process
• Hazard Identification and Determination of Acceptable Levels
• List of potential hazards that may be associated with a milk and milk product.
• Determination of the acceptable level for each identified food safety hazard.
•  
• Hazard Identification
• HACCP team develops a list of potential biological, chemical, and physical hazards that may be
introduced, increased, or controlled at each step described on the product flow diagram.
• The preliminary information collected while developing the product description
• Experience
• External information including, when possible, epidemiological and other historical data
• Information from the food chain on food safety hazards that may be of relevance for the safety of
the end products, intermediate products and the food at consumption
Determination of Acceptable Levels
• For each food safety hazard identified, its acceptable level in the end product shall be determined
whenever possible.
• This determination shall consider:
• Regulatory requirements
• Customer requirements
• Intended use by the customer
• Other relevant data
• Record the result of the determination and its justification.
•  
Hazard Evaluation
• Evaluation based on the likelihood of occurrence and the severity of effects of a particular hazard.
• Identify which of the potential hazards pose a significant risk to the consumer.
•  The HACCP team decides which of the potential hazards listed during hazard identification stage
present a significant risk to consumers.
• Each potential hazard should be evaluated based on two factors:
• Severity (of the potential illness or injury)
• Likelihood of occurrence
Evaluating Severity
• Will require consideration of various factors, including:
• Susceptibility of intended customers to foodborne illness (e.g. children versus adults)
• Possible impact of secondary problems
• Magnitude and duration of the illness or injury
Estimating Likelihood of Occurrence
•  
• Experience
• Data from past foodborne illness outbreaks
• Information in the scientific literature
• Historical information gathered by the establishment
Factors Influencing Likelihood of Occurrence
• Effectiveness of prerequisite programs
• Frequency of association of the potential hazard with the food or ingredient
• Method of preparation
• Conditions during transportation
• Expected storage conditions
• Likely preparation steps before consumption
•  
Control Measures

• Any action or activity that can be used to prevent or eliminate a food safety hazard, or reduce it to
an acceptable level.
• Often termed “Preventive Measures” in earlier HACCP documents.
• More than one control measure may be required for a specific hazard.
• More than one hazard may be addressed by a specific control measure.
Examples of Control Measures
• Filtration
• Pasteurization
• Thermal processing
• Acidification
• Fermentation
• Disinfection
• Refrigeration
• Freezing
Exercise
• How does you identify CP, CCP and SOP at your dairy Plant ? Group exercise by taking an example
of a process section each for a group.
• How would you make your food handler understand the importance of CP, CCP and SOP? 3-4 brief
experience sharing
• Too much of SOP at plant kills productivity ?Debate

• 60-90 minutes
 PART- XIV
• PEST CONTROL
Garbage lying
open – Source
of flies, insects,
rodents

Open &
unattended
garbage bins
Pest control Method Continue
Exercise
• Share the pest issues at your plant and how have you resolved them ?
• Share the emerging trends in pest control at your plant ?
• How does plant designing help in pest control at a dairy plant ?

• 20-30 minutes