HACCP in Dairy Industry

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QUALITY : 

Quality of foods, such as milk and milk products may be defined as that sum of all the characteristics which enable the food to satisfy definite requirements and which determines its fitness for consumption. (Molnar,1993) QUALITY

Slide 5: 

HACCP Hazard Hazard Identification and Analyses HACCP Plan Monitor

Prerequisites for the Application of HACCP : 

Food hygiene requirements and measures Management and supervision Facilities Supplier control Production equipment Maintenance, cleaning and sanitation Pest control Waste management Prerequisites for the Application of HACCP

Prerequisites for the Application of HACCP : 

Personal hygiene Health status Personal behaviour Visitors Receiving, storage and shipping Cross-contamination Training Packaging Prerequisites for the Application of HACCP

Five Preliminary Steps : 

Five Preliminary Steps

Assemble HACCP Team : 

Obtain top management commitment Appoint a leader and a secretary Assure participation of experts in QA, Microbiology, chemistry, food technology Assure co-operation of other experts Define scope of the study Assemble HACCP Team

STEP -1 : 

Assemble HACCP Team STEP -1 Recommendation Involve all departments that will be affected within the establishment.

Describe Product : 

Formulation and composition Raw materials & ingredients Parameters influencing safety Processing Packaging Distribution Describe Product

Step -2 : 

Describe Product Step -2 Product description List Product Ingredients & Incoming Material

Identify Intended Use : 

Food service establishments Caterers Hospitals General population Specific groups of the population Preparation practices Exportation Identify Intended Use

Construct Flow Diagram : 

Cover all steps which might have an Influence on the safety of the product Include important data such as time & Temperature Indicate hygiene level of areas and Barriers Construct Flow Diagram

Step - 4 : 

Construct Process Flow Diagram & Plant Schematic Step - 4 Identify Process Steps. Enough details to be useful in hazard identification.

On - site Confirmationof Flow Diagram : 

Check correctness of information Check whether important information was not overlooked Check during all periods of operation and cleaning, but also during idle hours Discuss practices with operators On - site Confirmationof Flow Diagram

Slide 17: 

7 HACCP Prin ci ples

Slide 18: 

1.Conduct a hazard analysis Identify hazards

Slide 19: 

1.Conduct a hazard analysis Identify hazards

Slide 20: 

1.Conduct a hazard analysis Identify hazards 2.Determine the critical control points(CCP) in the food preparation.

Slide 21: 

1.Conduct a hazard analysis Identify hazards 2.Determine the critical control points(CCP) in the food preparation.

Slide 22: 

1.Conduct a hazard analysis Identify hazards 2.Determine the critical control points(CCP) in the food preparation. 3.Establish critical limits for preventive measures.

Slide 23: 

1.Conduct a hazard analysis Identify hazards 2.Determine the critical control points(CCP) in the food preparation. 3.Establish critical limits for preventive measures.

Slide 24: 

1.Conduct a hazard analysis Identify hazards 2.Determine the critical control points(CCP) in the food preparation. 3.Establish critical limits for preventive measures. 4.Establish procedures to monitor CCP’s

Slide 25: 

1.Conduct a hazard analysis Identify hazards 2.Determine the critical control points(CCP) in the food preparation. 3.Establish critical limits for preventive measures. 4.Establish procedures to monitor CCP’s

Slide 26: 

1.Conduct a hazard analysis Identify hazards 2.Determine the critical control points(CCP) in the food preparation. 3.Establish critical limits for preventive measures. 4.Establish procedures to monitor CCP’s

Slide 28: 

5.Establish corrective action to be taken when monitoring shows that a critical limit has been exceeded.

Slide 29: 

5.Establish corrective action to be taken when monitoring shows that a critical limit has been exceeded.

Slide 30: 

5.Establish corrective action to be taken when monitoring shows that a critical limit has been exceeded. 6.Written HACCP Plan

Slide 31: 

5.Establish corrective action to be taken when monitoring shows that a critical limit has been exceeded. 6.Written HACCP Plan

Slide 32: 

5.Establish corrective action to be taken when monitoring shows that a critical limit has been exceeded. 6.Written HACCP Plan 7.Establish procedures to verify that the HACCP plan is working.

Slide 33: 

5.Establish corrective action to be taken when monitoring shows that a critical limit has been exceeded. 6.Written HACCP Plan 7.Establish procedures to verify that the HACCP plan is working.

Slide 34: 

HAZARD The potential to cause harm

BIOLOGICAL HAZARD : 

Any disease spreading organism found in food which may cause illness to the consuming individual. BIOLOGICAL HAZARD CHEMICAL HAZARD Any substance, used or in contact with Food, or developed by a chemical process or processes, which may cause illness to the consuming individual. PHYSICAL HAZARD Any physical matter not normally found in food which may cause illness or injury to the consuming individual.

Conduct a Hazard Analysis : 

list of steps in the process where significant hazards occur Cows Parlor Milker Cow Preparation Milking System Bulk Tank Conduct a Hazard Analysis

Identify the Critical Control Points : 

COW Identify the Critical Control Points

FLOOR : 

Floor Drop hoses Light - 150 lux unit Ventilation -150 cubic feet/ min of air exchange Milking pit FLOOR

Milking system : 

Daily checks on system function Basic understanding on the working of milking machine Milker Cow handling Detecting Mastitis cows, identifying and reporting Recognizing the importance of cows treated with Antibiotics Milking system

BULK TANK : 

Bulk tank temperature, monitored daily Temperature must reach 40 F within 2 h of milking and hold Milk agitator BULK TANK

Cow Preparation : 

Udder, teat and teat end condition Cleanliness ( manure, feed, bedding) Milking process Cow Preparation

Principle 3 : 

Establish Critical Limits Principle 3 If we exceed a critical limit, a potential hazard exists! More than 1 critical limit may exist. YIKES! What’s next?

Principle 4 : 

Monitoring Procedures Principle 4 Monitoring procedures determine if critical limits are out of control.

Principle No. 5 : 

Establish corrective action to be taken when monitoring indicates that there is a deviation from an established critical limit. Principle No. 5

Principle No. 6. : 

Establish procedures for verification that the HACCP system is working correctly. Monthly bulk tank milk reports Principle No. 6. Is my HACCP plan working?

Establish Effective Record-keeping : 

Daily Check lists and records Example: Bulk tank milk Temperature Monthly Check lists and records Example: individual cow SCC Six Monthly Check lists and records Example: Milking system inspection Establish Effective Record-keeping

Raw Milk Supply : 

Raw Milk Supply

Raw Milk Supply : 

High Acidity - may indicate either - Sour milk: due to growth of bacteria including pathogens OR - Chemical adulteration by an acidic product or cleaner. Low Acidity - indicates chemical adulteration by a soap or cleaner. Milk Temperature At temperatures >4°C, pathogen growth is accelerated. Presence of Antibiotics: Consumption of milk products containing antibiotics can, in certain cases, produce severe allergic reactions that could result in death. Raw Milk Supply

Pasteurization : 

Pasteurization

Pasteurization : 

Good Practice for High Temperature Short Time Pasteurization

Vat Pasteurization : 

Vat Pasteurization

Vat Pasteurization : 

Vat Pasteurization

Ice Cream Pasteurized Product Supply : 

Ice Cream Pasteurized Product Supply

Cheese : 

Cheese

Butter : 

Butter

Fluid Milk : 

Fluid Milk

Ingredients/Packaging Materials : 

Ingredients/Packaging Materials

Ingredients/Packaging Materials : 

Receipt of Ingredients: Every step in the loading/transport process increases the likelihood that containers may be contaminated (chemical, pest). Supplier Standards: Requesting standards for each ingredient from your supplier(s) will help ensure that all ingredients are food grade and microbiological/chemical standards for finished products are met. Storage of Ingredients: Improper storage of ingredients can result in an adulterated finished product. All food ingredients must be stored away from potential non-food contaminants such as oil, cleaners, etc. Ingredients/Packaging Materials

Finished Product Storage : 

Finished Product Storage

Dairy Plant - Universal Control Points : 

Dairy Plant - Universal Control Points

Benefits : 

Higher level of confidence Safe product Quality product Sooner rather than later Trouble shooting approach Minimized rework Employee involvement Improved employee morale, Empowerment, ownership, Accountability satisfaction Organization Profitable operation Benefits

Challenges : 

People Address new stresses, responsibilities & challenges Affirm roles & responsibilities Processes Individual process evaluation for all products Equipment Performance & maintenance Excessive Paperwork Cost of training & Implementation Challenges

On-Going Benefits : 

Identifies problems Review standards manuals & facilities Conforms to specs Reduce customer complaints Quality improvement in raw materials On-Going Benefits

Steps to HACCP Success : 

1. COMMITMENT from top management for food safety(Most important step) 2. RESPONSIBLE Personnel to develop, implement and maintain HACCP plan 3. CONSISTENT monitoring of records for accuracy with a corrective action procedure in place 4. VERIFY activities on a routine basis 5. UPDATE and revise HACCP plan as needed 6. ADEQUATE training for ALL employees Steps to HACCP Success

Government Policy and Strategies : 

Government Policy and Strategies

Conclusion…… : 

ENHANCE employee satisfaction providing ownership in being a part of the overall food safety process ASSIST in the manufacturing of safe products ASSURE consumers that the food supply is as safe as possible INCREASE confidence regarding shared food safety priorities (communication/trust –regulatory/industry relationship) PROVIDE regulatory with a level of confidence that the safety of the plant processes are in control everyday Conclusion……