The simplest, yoghurt.
I have drafted a process diagram in two parts:


Will edit based on comments from members then number the steps.
Regards,
Tony
Posted 22 November 2010 - 03:40 AM
The simplest, yoghurt.
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Posted 23 November 2010 - 08:15 AM
Tony has started this topic so that members can work through an example of a risk assessment together identifying hazards and control measures to try to improve understanding of the PRP, ORP, CCP cunundrum.
Please get involved whether or not you have Yoghurt knowledge or are an ISO / FSSC 22000 expert.
Regards,
Simon
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Posted 23 November 2010 - 05:05 PM
I have drafted a process diagram in two parts:
Yoghurt Process Flow Diagram Part 1.pdf 78.53KB 1915 downloads
Yoghurt Process Flow Diagram Part 2.pdf 78.3KB 1391 downloads
Will edit based on comments from members then number the steps.
Regards,
Tony
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Posted 24 November 2010 - 07:36 AM
Only thing i would have done differently is having strike pH and cooling separate. Also i didn't see an addition of sugar.
Obviously this is for a natural stirred yogurt.
Caz x
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Posted 25 November 2010 - 02:44 PM
Simple Simon says...Thanks Caz.
Simon asked for it to be kept simpleSo Natural Stirred it is. I think we can add to it at a later date.
Kind regards,
Tony
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Posted 25 November 2010 - 02:52 PM
I've never worked in yoghurt; can you explain to me the process in a quick paragraph? Thanks matees.
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Posted 25 November 2010 - 03:04 PM
Simple Simon says...
![]()
So what are we doing at the moment - agreeing the process flow?
What happens next in the process?
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Posted 25 November 2010 - 03:12 PM
I've never worked in yoghurt; can you explain to me the process in a quick paragraph? Thanks matees.
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Posted 26 November 2010 - 04:41 PM
Sorry GMO missed your post:
Get some milk
Fortify it/adjust the fat level
Pasteurise/Homogenise
Cool to 40 C for Incubation
Add a nice bacteria
Let it grow and generate lactic acid so increasing the acidity/ reducing the pH and coagulating the proteins
Stop the incubation at the right pH say < 4.6 by cooling it. At the same time filtering which will also texturise
Pack it
Cool some more
Send off to customer
Regards,
Tony
Posted 27 November 2010 - 03:10 AM
Probably add some sugar at the fortifying stage!! ;o)
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Posted 28 November 2010 - 11:39 AM
Prerequisite Programmes - In establishing prerequisites I propose to be guided by ISO 22000:2005 & PAS 220:2008/ISO_TS_22002-1 2009
From ISO 22000 Clause 7.2.3 *
From PAS 220/ISO_TS_22002-1 **
* a)construction and lay-out of buildings and associated utilities
**4. Construction and layout of buildings
4.1 General requirements
4.2 Environment
4.3 Locations of establishments
*b)lay-out of premises, including workspace and employee facilities
**5. Layout of premises workspace
5.1General requirements
5.2 Internal design, layout and traffic patterns
5.3 Internal structures
5.4 Location of equipment
5.5 Laboratory facilities
5.6 Temporary/mobile premises and vending machines
5.7 Storage of food, packaging materials, ingredients and non food chemicals
*c)supplies of air, water, energy and other utilities
**6. Utilities – air, water, energy
6.1 General requirements
6.2 Water supply
6.3 Boiler chemicals
6.4 Air quality ventilation
6.5 Compressed air and other gases
6.6 Lighting
*d)supporting services, including waste and sewage disposal
**7. Waste disposal
7.1 General requirements
7.2 Containers for waste and inedible or hazardous substances
7.3 Waste management and removal
7.4 Drains and drainage
*e)the suitability of equipment and its accessibility for cleaning, maintenance and preventative maintenance
**8. Equipment suitability, cleaning and maintenance
8.1 General requirements
8.2 Hygienic design
8.3 Product contact surfaces
8.4 Temperature control and monitoring equipment
8.5 Cleaning plant, utensils and equipment
8.6 Preventive and corrective maintenance
*f)management of purchased materials (e.g. raw materials, ingredients, chemicals and packaging), supplies (e.g. water, air, steam and ice), disposals (e.g. waste and sewage) and handling of products (e.g. storage and transportation);
**9. Management of purchased materials
9.1 General requirements
9.2 Selection and management of suppliers
9.3 Incoming material requirements (raw/ingredients/packaging)
*g)measures for the prevention of cross contamination
**10. Measures for prevention of cross contamination
10.1 General requirements
10.2 Microbiological cross contamination
10.3 Allergen management
10.4 Physical contamination
*h) cleaning and sanitizing
**11. Cleaning and sanitizing
11.1 General requirements
11.2 Cleaning and sanitizing agents and tools
11.3 Cleaning and sanitizing programmes
11.4 Cleaning in place (CIP) systems
11.5 Monitoring sanitation effectiveness
*i)pest control
**12. Pest control
12.1 General requirements
12.2 Pest control programmes
12.3 Preventing access
12.4 Harbourage and infestations
12.5 Monitoring and detection
12.6 Eradication
*j)personnel hygiene
**13. Personnel hygiene and employee facilities
13.1 General requirements
13.2 Personnel hygiene facilities and toilets
13.3 Staff canteens and designated eating areas
13.4 Work wear and protective clothing
13.5 Health status
13.6 Illness and injuries
13.7 Personal cleanliness
13.8 Personal behaviour
**14. Rework There is no reworking of the product14.1 General requirements
14.2 Storage. Identification and traceability
14.3 Rework usage
**15. Product recall procedures
15.1 General requirements
15.2 Product recall requirements
**16. Warehousing
16.1 General requirements
16.2 Warehousing requirements
16.3 Vehicles, conveyances and containers
**17. Product information/consumer awareness
17.1 Product information
17.2 Labelling of pre-packaged foods
**18. Food defence, biovigilance and bioterrorism
18.1 General requirements
18.2 Access controls
*k)other aspects as appropriate - I suggest we add:
Control of Yeast & Moulds in the Environment
Control of Bacteriophages in the Envrionment
Please feel free to add to the list.
Thanks,
Tony
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Posted 28 November 2010 - 01:54 PM
On waste, what happens to it as it's a product of animal origin? Can it be sold onto animal feed manufacturers or dried and used for some purpose? There is presumably a lot of calories and value in any waste and a high cost of disposal.
Other prerequisite programmes:
Training & recruitment of suitable staff
Does 13.5 include pre-employment screening and visitor screening?
Traceability in general (even though we don't have rework)
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Posted 29 November 2010 - 02:43 AM
On waste, what happens to it as it's a product of animal origin? Can it be sold onto animal feed manufacturers or dried and used for some purpose? There is presumably a lot of calories and value in any waste and a high cost of disposal.
Other prerequisite programmes:
Training & recruitment of suitable staff
Does 13.5 include pre-employment screening and visitor screening?
Traceability in general (even though we don't have rework)
People known or suspected to be infected with, or carrying, a disease or illness transmissible through food shall be prevented from handling food or materials which come into contact with food.
Edited by Tony-C, 29 November 2010 - 02:44 AM.
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Posted 29 November 2010 - 04:12 AM
Hi Tony,
It’s certainly an interesting product.
Not sure how typical I am but, being a (totally-non-familiar-with-the-process) reader, I found that I had to do a little more basic process reading to appreciate yr flow chart / comments to GMO. I now hesitate to use the word “simple”, even with irony.
As a result, I might suggest the basic links and attachment below for anybody else in similar ignorance. Commercial variations of the steps/ numbers mentioned seem to be legion so the content is primarily illustrative although structured, I think, not too different to yr original, more detailed, layout.
http://www.milkfacts... Production.htm
http://www.foodsci.u...edu/yogurt.html
Yoghurt.doc 34.5KB
393 downloads
Rgds / Charles.C
Kind Regards,
Charles.C
Posted 30 November 2010 - 12:35 AM
recall procedure
Document and record control procedure
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Posted 01 December 2010 - 02:47 AM
Anyone want to offer up a Product Description for a Natural Stirred Yoghurt?
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Posted 03 December 2010 - 11:48 AM
On waste, what happens to it as it's a product of animal origin? Can it be sold onto animal feed manufacturers or dried and used for some purpose? There is presumably a lot of calories and value in any waste and a high cost of disposal.
Posted 03 December 2010 - 11:49 AM
Anyone want to offer up a Product Description for a Natural Stirred Yoghurt?
Posted 11 December 2010 - 05:16 AM
I'll post an example spec / flow diagram when i get a chance.
Caz x
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Posted 11 December 2010 - 06:33 AM
Dear Tony,
Thks for the starter.
Have "quality-safety" / micro. factors been intentionally omitted due unrequired for this specification purpose or are you simply awaiting suggestions ?
For local market only ? I noticed that legal composition data (and other things ??) may sometimes apply depending on destination. Just inquiring.
Rgds / Charles.C
Kind Regards,
Charles.C
Posted 11 December 2010 - 09:09 AM
Dear Tony,
Thks for the starter.
Have "quality-safety" / micro. factors been intentionally omitted due unrequired for this specification purpose or are you simply awaiting suggestions ?
For local market only ? I noticed that legal composition data (and other things ??) may sometimes apply depending on destination. Just inquiring.![]()
Rgds / Charles.C
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Posted 14 December 2010 - 01:42 PM
It’s such a great ideato make an example of risk analysis, which would be useful for FS staff overthe whole World.
I’m a little disappointed.There are over 9000 members that are keeping an eye on these forums and askingfor help, taking documents. Isn’t it about time to give a little bit of yourknowledge back?
Come on, don’t be boring. Share. It's Christmas time
Tony,
Wouldn't it be better to make some structure for this project?
Are we some place in ISO22000 - 7.3. Preliminary steps to enable hazard analysis?
7.3.3.1 Raw materials, ingredient and product-contact materials
Raw materials (from your product description example)
- Raw milk,
-skimmed milk powder
-milk proteins (???)
7.3.4.
Intended use:
As a snack yoghurt or as an ingredient for cold RTE (f.ex., in dressingfor pasta salads) Not for cooking.
Edited by Inesa, 14 December 2010 - 01:44 PM.
Posted 14 December 2010 - 02:22 PM
Tony,
Wouldn't it be better to make some structure for this project?
Are we some place in ISO22000 - 7.3. Preliminary steps to enable hazard analysis?
7.3.3.1 Raw materials, ingredient and product-contact materials
Raw materials (from your product description example)
- Raw milk,
-skimmed milk powder
-milk proteins (???)
7.3.4.Intended use:
As a snack yoghurt or as an ingredient for cold RTE (f.ex., in dressingfor pasta salads) Not for cooking.
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Posted 14 December 2010 - 07:19 PM
Dear Inesa,
Now you have 8999 awaiting yr input
I started to put some bits together but unfortunately got diverted to easier tasks, + cake.
(No offence Tony, I do agree with Inesa, it's a very worthwhile project, but it is not simple IMO, despite Charles Chew's one line conclusion elsewhere in this forum
)
Rgds / Charles.C
Kind Regards,
Charles.C
Posted 14 December 2010 - 09:33 PM
I will find Dairy processing handbook and be back
Edited by Inesa, 15 December 2010 - 12:53 AM.
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