91 replies to this topic

[Tony-C]

The simplest, yoghurt.

I have drafted a process diagram in two parts:

 Yoghurt Process Flow Diagram Part 1.pdf   78.53KB   1930 downloads

 Yoghurt Process Flow Diagram Part 2.pdf   78.3KB   1404 downloads

Will edit based on comments from members then number the steps.

Regards,

Tony

[Simon]

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

[cazyncymru]

I have drafted a process diagram in two parts:

 Yoghurt Process Flow Diagram Part 1.pdf   78.53KB   1930 downloads

 Yoghurt Process Flow Diagram Part 2.pdf   78.3KB   1404 downloads

Will edit based on comments from members then number the steps.

Regards,

Tony

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

[Tony-C]

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

Thanks Caz.
Simon asked for it to be kept simple So Natural Stirred it is. I think we can add to it at a later date.

Kind regards,

Tony

[Simon]

Thanks Caz.
Simon asked for it to be kept simple So Natural Stirred it is. I think we can add to it at a later date.

Kind regards,

Tony

Simple Simon says...

So what are we doing at the moment - agreeing the process flow?

What happens next in the process?

[GMO]

I've never worked in yoghurt; can you explain to me the process in a quick paragraph? Thanks matees.

[Tony-C]

Simple Simon says...

So what are we doing at the moment - agreeing the process flow?

What happens next in the process?

Yes I will give it a few days for any comments on the process flow then .......... How about:

Define Prerequisite Programmes
Define Product Characteristics
Define Intended Use

[Tony-C]

I've never worked in yoghurt; can you explain to me the process in a quick paragraph? Thanks matees.

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

[cazyncymru]

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

Probably add some sugar at the fortifying stage!! ;o)

[Tony-C]

Probably add some sugar at the fortifying stage!! ;o)

I definitely think you've got a sweet tooth Caz

[Tony-C]

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 product
14.1 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

[GMO]

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)

[Tony-C]

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)

Thanks GMO,

13.6 requires

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.

There are a variety of routes for disposal. I think we should say that the prerequisite is that it is controlled so that it does not affect food safety.

Regards,

Tony

Edited by Tony-C, 29 November 2010 - 02:44 AM.

[Charles.C]

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   402 downloads

Rgds / Charles.C

[AS NUR]

recall procedure
Document and record control procedure

[Tony-C]

Anyone want to offer up a Product Description for a Natural Stirred Yoghurt?

[cazyncymru]

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.

Waste yogurt would need to have a Cat note (Cat 1,2 or 3) before it is removed from the manufacturing site.
The Dairy and the receiver needs to be registered with both the local EHO and DEFRA under the Animal By Products legislation

Caz x

[cazyncymru]

Anyone want to offer up a Product Description for a Natural Stirred Yoghurt?

I'll post an example spec / flow diagram when i get a chance.

Caz x

[Tony-C]

I'll post an example spec / flow diagram when i get a chance.

Caz x

Thanks

Feel free to add to this.

 Product Description Yoghurt.pdf   131.09KB   525 downloads

Regards,

Tony

[Charles.C]

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

[Tony-C]

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

Thank you Charles. Yes a bit of a kick start.

I would like members to contribute their ideas as to what they would inlcude. Any suggestions for quality/safety & composition that you have are welcome.

Regards,

Tony

[Inesa]

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.

[Tony-C]

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.

Hi Inesa,

Thanks for your post.

Sorry if the structure wasn't outlined as we are encouraging members to contribute. I see the structure following Section 7 of ISO 22000 although I have a tendancy to jump around (It is one of my favourite songs) a little bit.


7.1 General - Skipped this
7.2 Prerequisite programmes (PRPs) - we've had contributions on this

So we are here 7.3 Preliminary steps to enable hazard analysis:
7.3.3.2 Characteristics of end products (More contributions welcome - I did this first as our members needed to know a product make up before we move to 7.3.3.1 Raw materials, ingredients and product-contact materials then 7.3.4 Intended use etc. etc.

By the way I did a basic flow diagram (7.3.5.1 Flow diagrams) to give members that are not familiar with the product an idea of the process.

I am not hung up on intended use although I believe that as a snack for children or the old folks would mean that we would want to apply stringent standards/controls.

So if anyone wants to contribute descriptions of ingredients and product-contact materials it would be appreciated:
Milk
Skimmed milk powder
Milk proteins
Printed Polyethylene terephthalate (PET) Pot
Printed Aluminium foil lid

Including the following as appropriate:
a) biological, chemical and physical characteristics
b) composition of formulated ingredients
c) origin
d) method of production
e) packaging and delivery methods
f) storage conditions and shelf life
g) preparation and/or handling before processing
h) food safety-related acceptance criteria or specifications

Kind regards,

Tony

[Charles.C]

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

[Inesa]

I will find Dairy processing handbook and be back

Edited by Inesa, 15 December 2010 - 12:53 AM.