HACCP Plan for dairy desserts

Hi Everyone

For my Uni project I have to create a HACCP plan for a dairy desserts, from pasteurized milk. Just a brief description: 2 types of desserts, milk mousse( mixture of pasteurized milk, sugar, flavouring and thickeners) and a creamy cream caramel( mixed milk, flavouring, sugar, thickeners and, caramel). As I'm not familiar with dairy processing especially prerequisite and shelf life evaluation can I kindly ask my more experienced forum colleagues to direct me to some learning materials or regulations etc.

Also how to set and evaluate the shelf life of this products, will addition of an air into mousses decreases shelf life and addition of sugar increases it? based on the pasteurized milk shelf life of average 12-21 days and addition of sugar and other dry ingredients is a 11 days realistic ?

Regarding Flow diagram will it be 1. intake of milk (CCP), intake of dry ingredients (CCP), 2. mixing( whipping), 3. filling ( in case of mousse air flush just before filling), 4. lidding, 5. packing, 6 chilled storage(CCP)prior dispatch, 7 chilled dispatch(CCP)

Hi Everyone

For my Uni project I have to create a HACCP plan for a dairy desserts, from pasteurized milk. Just a brief description: 2 types of desserts, milk mousse( mixture of pasteurized milk, sugar, flavouring and thickeners) and a creamy cream caramel( mixed milk, flavouring, sugar, thickeners and, caramel). As I'm not familiar with dairy processing especially prerequisite and shelf life evaluation can I kindly ask my more experienced forum colleagues to direct me to some learning materials or regulations etc.

 

 

Also how to set and evaluate the shelf life of this products, will addition of an air into mousses decreases shelf life and addition of sugar increases it? based on the pasteurized milk shelf life of average 12-21 days and addition of sugar and other dry ingredients is a 11 days realistic ?

 

Regarding Flow diagram will it be 1. intake of milk (CCP), intake of dry ingredients (CCP), 2. mixing( whipping), 3. filling ( in case of mousse air flush just before filling), 4. lidding, 5. packing, 6 chilled storage(CCP)prior dispatch, 7 chilled dispatch(CCP)

Hi agness88,

You will need to consider the cup weight of the mousse, pasterizing the mix and cooling within 6hours for example, date coding and metal checking within the process. I have attached an example of a dairy product that is different but you shoukld get the gist of CCP's. If you excahange 'oven' for 'kettles' on the flow diagram and temp to 90°C not 75°C you wont be far odd

DW

Thanks 

Hi agness88,

 

You will need to consider the cup weight of the mousse, pasterizing the mix and cooling within 6hours for example, date coding and metal checking within the process. I have attached an example of a dairy product that is different but you shoukld get the gist of CCP's. If you excahange 'oven' for 'kettles' on the flow diagram and temp to 90°C not 75°C you wont be far odd

 

DW

thank you daddywels for the Example of CCP. 

regard pasteurization of the mix you have suggested 90 C instead of 75C will that not change the structure and taste qualities of the final product? 

Hi agness88,

I worked at a dairy desserts factory about 10 years ago, and we had the following flow for mousse:

Intake (milk, eggs, dry goods, packaging etc.), storage (chilled), mix and cook (inc. pasteurisation), flavour, whip, fill, seal, code, metal detect, pack, blast chiller, chilled store, chilled dispatch.

Sometimes the flavouring and whipping was done off line, depending on demand for resources.

Pasteurisation and metal detect were CCPs.

First stage including the pasteurisation was low risk, next including packing was high care, then low risk again. 2 separate HACCP plans as the first low risk was common to many products, as was the second stage (plug and play saves time).

12 day shelf life

Thanks 

 

thank you daddywels for the Example of CCP. 

regard pasteurization of the mix you have suggested 90 C instead of 75C will that not change the structure and taste qualities of the final product? 

Hi agness88

As i imagine its dairy High Risk filled i would recommend 90°C, if you have a robust recipe & cooled efficiently it will be fine. In my experience of recipes it will be quite liquid when it remove into a BOM then when you set it up and get the cup weight it will hopefully be a nice stable airated product. It would be pasterized in a kettle with a heated jacket and slowly turned and in some cases agitated so blended correctly. A short time at 90°C is fine and shouldnt curdle. The recipe is also key in bad things happening / not happening. :oops2:

DW

Hi agness88,

 

I worked at a dairy desserts factory about 10 years ago, and we had the following flow for mousse:

Intake (milk, eggs, dry goods, packaging etc.), storage (chilled), mix and cook (inc. pasteurisation), flavour, whip, fill, seal, code, metal detect, pack, blast chiller, chilled store, chilled dispatch.

Sometimes the flavouring and whipping was done off line, depending on demand for resources.

Pasteurisation and metal detect were CCPs.

First stage including the pasteurisation was low risk, next including packing was high care, then low risk again. 2 separate HACCP plans as the first low risk was common to many products, as was the second stage (plug and play saves time).

12 day shelf life

Thank you BrummyJim 

if the pasteurization was a ccp how was the chilled storage and dispatch controlled (prerequisite?), would a disruption of a cold chain  reduce the shelf life? 

Chiller temperatures were on continuous monitoring with a datalogger. Dispatch was difficult to manage during hot summers though as there was regular loading of vehicles.

Hi 

GrumpyJimmy and BrummyJim do you know if  different methods of filling will affect product safety/quality? I mean if aerated products such as mousses will have different safety concerns than whipped ones? 

What metal detection test pieces should be used for 100ml cups? is there any regulation which sets test pieces sizes?