9 replies to this topic

[Piyush0680]

Hi all,

We are going to manufacture a new product called non dairy creamer and want to understand the risks involved in it. Does anyone have a HACCP plan for non dairy creamer?

Thanks & Regards,

Piyush

[Abdul Qudoos]

Hi all,

We are going to manufacture a new product called non dairy creamer and want to understand the risks involved in it. Does anyone have a HACCP plan for non dairy creamer?

Thanks & Regards,

Piyush

Greetings Piyush,

What kind of process do you have? can you share process flow diagram and raw material used?

I am using spray dried, vegetable origin non-dairy creamer (derived from hydrogenated soybean oil).

Abdul Qudoos

[Piyush0680]

Hi Abdul,

Raw material which we use are hydrogenated veg. oil, maltodextrin, disodium phosphate and flavours. We are going to manufacture in liquid form and not spray dry it. Once mix, we would store the mix at 50 celsius and then UHT treat it before filling it aseptically.

What are the risks/hazards involved in this product? Does we need to keep certain target group for its consumption in focus.

Appreciate your kind help on it.

Regards,

Piyush

[Abdul Qudoos]

Hi Abdul,

Raw material which we use are hydrogenated veg. oil, maltodextrin, disodium phosphate and flavours. We are going to manufacture in liquid form and not spray dry it. Once mix, we would store the mix at 50 celsius and then UHT treat it before filling it aseptically.

What are the risks/hazards involved in this product? Does we need to keep certain target group for its consumption in focus.

Appreciate your kind help on it.

Regards,

Piyush

Hassle free process (No chance of Risks / Hazards)
Lets start with Raw material store,

• arranging of raw materials & packing materials
• QC check required for inspection and cross-checking of RM weights according to formulation (excess or low can effect the product characteristics like flavor, disodium phosphate)
• filtering hydrogenated soybean oil and other liquid ingredients and seiving through mesh for powdered ingredients. and
• dosing directly to the mixing tank (online monitoring by QC personnel & production supervisors for any physical hazards)
• mixing and heating 50 celsius (Quality check by QC meets with specification, records need to keep for temperature and QC tests)
• UHT treatment (CCP) proper temperature, all records and graphical data (if graph is available on line) need to maintain. if temp low or very high then involvement of hazard that's why CCP. if not meets requirement rework again
• filling aseptically (QC check and laboratory testing/analysis required meets with specification) again rework if not met requirement
• metal detector if filling in plastic bags/cartons or buckets, if it is tin or glass with aluminum caps the step should be at filling.
• the ready batch should be kept at cool for tempering.
• after tempering for certain period release it.
• distribution.

Hope you understand and got IDEA and met with your requirement,
Also when you finished please share with us.

[Piyush0680]

Hi Abdul,

A very thanks for your reply with detailed flow process. But, I think that you misread me as I am looking for any definite risks(microbial, physical or chemical) which should I look in before we start its production and while defining the control measures.

I know one thing for sure that I need to focus on aerobic spores as microbial risk to the product and hydrogen peroxide residues as we are going to aseptically pack the product. Thus, I want to understand such type of risks involve in non-dairy creamer which I should be knowing it and proactively controlling it.

Thanks & Regards,

Piyush

[AS NUR]

Hi Abdul,

A very thanks for your reply with detailed flow process. But, I think that you misread me as I am looking for any definite risks(microbial, physical or chemical) which should I look in before we start its production and while defining the control measures.

I know one thing for sure that I need to focus on aerobic spores as microbial risk to the product and hydrogen peroxide residues as we are going to aseptically pack the product. Thus, I want to understand such type of risks involve in non-dairy creamer which I should be knowing it and proactively controlling it.

Thanks & Regards,

Piyush

dear piyush..

Now i am working for NDC Producer In INdonesia and we allready held ISO 22000 certificate...

To control your micro, first you have to look at your country regulation, and in Indonesia for NDC product we have to concern on E. Coli, Staphylococcus, Salmonella, Enterobacteriacea.. And I think for liquid NDC have same risk .

So.. for potential contamination micro, you have to consider those micro.. and the micro can came from RM, Environment, Production process and human.

IMEX...we using PRP (GMP) to control micro during the process preparation, operational
and cleaning process. and .. IMO.. for your process, you have to put pasteurizing or UHT process as CCP to control it, because that process can reduce the micro to acceptable level...

The last... For the other potential hazard (physical and chemical) depend on your process.. you can put residual cleaning agent as chemical hazard and foreign matter (metal files or the other contaminat) as physiscal hazard..

thats my opinion.. hope can help you...

[Abdul Qudoos]

Hi Abdul,

A very thanks for your reply with detailed flow process. But, I think that you misread me as I am looking for any definite risks(microbial, physical or chemical) which should I look in before we start its production and while defining the control measures.

I know one thing for sure that I need to focus on aerobic spores as microbial risk to the product and hydrogen peroxide residues as we are going to aseptically pack the product. Thus, I want to understand such type of risks involve in non-dairy creamer which I should be knowing it and proactively controlling it.

Thanks & Regards,

Piyush

Dear Piyush,
Good Morning, please find below my anwer hope it meets your requirement:

microbial - as said by AS NUR + treated water / potable water details & analysis, filtration process data (if any) and bacteriological analysis of water (residual chlorine neutralized - Total coliforms & Fecal coliforms, result should be Not detected)

physical - wood peices from pallets, boxes; metal (screw, blade, bolt, nut, metal scales out from machinery, etc.) from plant machinery, swarf etc, or wihtin raw materials or from employees; glass peices from packaging materials such as bottles and jars, light fittings, utensils, process equipment such as gauges; paper-peice or polythene plastic peice from raw material packaging materials, thread from packaging materials (stiched); hair from workers, etc.

chemical - Hygiene and disinfectant products, any residue, machine lubricants from process machinery and equipment, ink from ink-jet printer if using for date coding (make a list and give location, store away from production)

I have given definite risks (microbial, physical or chemical) please have a look and define control measures accordingly.

The best regards,

[Piyush0680]

Thanks AS NUR and abdul for your valuable input. It has provided me more insight for my planning to conduct hazard analysis.

If you have your HACCP plans for NDC, can you share it with me. It would be more helpful to me.

Thanks,

Piyush

[Ganesh]

Hi Piyush,

In your process the risks involved are allergens and may be heavy metals (based on the raw material supplier). Since you have UHT process the microbiological risk would be post process during aseptic filling. Seal integrity is very essential to ensure the product remains sterile in the supply chain. Physical hazards are controlled in the fine filters used for UHT process that would be the CCP

I am not sure of what UHT (Direct or Indirect) process you use, as in a TETRA kind of setup there are integral risks that you need to consider

If you need specific support please share the flow diagram of your process

Ganesh

[Simon]

Can you share your flow diagram Piyush, the members are willing to help and it would help them to give you better information if you could post it.

Regards,
Simon