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Site:
Scope

The HACCP study covers the manufacture and packing of stirred yogurt types from milk intake, raw milk storage, yogurt base blending, standardisation, homogenisation ,
heat treatment, cooling, inoculation of tanks, incubation, potting of yogurt, cooling, storage and distribution to customers for end use by consumers.

Product:
Composition:
Structure:
Processing
Packaging:
Storage / Distribution
Required Shelf Life:
Instructions for Use:
Intended Use by Consumer:

Stirred Yogurt, including Biolive and Probiotic yogurts

Raw Cow's milk
Homogenous blend of dairy ingredients and ingredients and flavourings in liquid form
Blending, standardisation, homogenisation, heat treatment,cooling and innoculation with bacterial dairy starter, incubationmixing of ingredients, potting and cooling.
Polystyrene pots multipack format, rPet Single pot format, Polystyrene Single Pots, Polypropylene single pots. PET lids or Foil lids. Polypropylene or rPet Overcaps
Chilled below 5C, target 1 - 5C maximum 5C
To XXXX specification of target 23/25 or 27 days, minimum 16 days into depot.
Keep refrigerated 1 - 5C or see Customer specification details. Use within three days of opening - retail packs only.
All population, without further processing excluding children of certain age groups. - See below.

Legislation:

Food Safety Act 1990 and all subsequent legislative documents and amendments there under. Codex alimentarius, Allergen Legislation 2003 /89EC Amendment Directive
2000 /13EC. Animal By Products Regulations 2005, Food Labelling regulations 2004, Food Hygiene) Wales regulations 2006, Yogurt Code of Practice. Plastic Materials
and Articles in Contact with Food Regulations 1998 (as amended)

Related Documents
Micro/chemical criteria
Hazards identified
Allergen Advice
Health Guidance to Consumers:

FSQ-002 Management of Food Safety and HACCP; FSQ-002 APP1 Pre Requisite Programme
See XXXX Laboratory Work Instructions
The hazards that the study will be used to identify include Microbiological (M), Physical (P) Chemical (C) and Allergenic (A)
Contains Milk Not suitable for babies under 4 months old

HACCP TEAM MEMBER

Carolyn Mills (Team Leader)
Richard Cooper
Jo Tett-Davies
Mark Williams
Trevor Stables
Elin Davies
Ben Kinsey
Katie Lea
Lesley Daniel

Verified By

JOB FUNCTION
Quality Control Manager
Operations Manager
Technical Manager
Senior Engineer
Senior Engineer
Quality Development Officer
NPD Technologist
Innovations Manager
Production Planner

HACCP RESPONSIBILITY
Team Leader
Production
Technical
Engineering
Engineering
Technical
Technical
NPD
Planning

Date Verified

TRAINING
RIPHH HACCP Principles - Int
RIPHH HACCP Principles - Int
RIPHH HACCP Principles - Int
RIPHH HACCP Principles - Int
RIPHH HACCP Principles - Int
RIPHH HACCP Principles - Int
RIPHH HACCP Principles - Int
RIPHH HACCP Principles - Int
RIPHH HACCP Principles - Int

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Completion Date

Completed By

NS

11/21/2008

C Mills

New Study to bring into line with changes to BRC Version 5

UR
SR
UR
UR
UR
UR

12/28/2008
6/29/2009
10/12/2009
12/18/2009
12/28/2009
2/4/2010

C Mills

Addition of Lesley Daniel to HACCP Team

C Mills
C Mills
C Mills
C Mills
C Mills

Scheduled Review of HACCP

Change pot format to PP, PS, rPet etc
Plastic Materials and Articles in Contact with Food Regulations 1998 (as amended)
Add Allergenic as stand alone
Review of Distribution Temperatures

REASON FOR HACCP STUDY:

Note: New Study (NS) / Scheduled Review (SR) / Unscheduled Review (UR)

Comments

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HACCP Flow Diagram for Stirred Yogurt

1. Raw Milk & Ingredient Purchasing
2. Raw Milk Reception CCP1
3. Raw Milk Storage

4. Preheating & Separation of some

Raw Milk into Skim Milk & Cream

6. Reconstitution of SMP with

Thermised Skim Milk

5. Thermisation and Cooling of Skim

Milk

Cream

7. Blending of Raw Milk with Skim

Milk/SMP/WPC/SMC/Cream/Sugar as
applicable.

8. Heating & Homogenisation

9. Thermal Treatment CCP2

10. Cooling and transfer to Inoculation

Tanks

11. Inoculation of Yogurt Base

12. Incubation of Yogurt Base CCP3

14. Pumping and Mixing of Yogurt

Base & Ingredients
Waste Disposed of via Category Note and
Approved Waste Carrier. No Rework.

Recovered Bulk

15. Pot Filling, Sealing & Coding

16. Blast Chilling

17. Sleeving of Multipacks/Addition of

Top Hat Overlids

18. Metal Detection CCP4

19. Cold Storage & Despatch

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Risk Analysis
To assess the likely occurrence of hazards and the severity of their adverse health effects, XXXX Dairy require the following quantitive evaluation of the presence of hazards to be carried out based on management knowledge and
experience, using hisotical data also where available.

Definition of Risk: An estimate of the LIKELIHOOD of the hazard occuring and its IMPACT on health.
RISK = IMPACT x LIKELIHOOD
e.g. probability of hazard occuring.

Assessment
This assessment shall be carried out using the following scores;
For the likelihood of a hazard occuring, allocate a figure from the horizontal axis on the chart above, and record the reason.
Assess how severe the impact would be on food safety / customer health by allocating a value from the vertical axis, and record the reason.

Record the risk by multiplying the score.

Likelihood

Impact

Risk Assessment

Red
Yellow
Green

3. Critical
2. Serious
1. Negligible

Probable.

Occasional

Improbable

9
6
3

6
4
2

3
2
1

Food Safety Risk if not controlled. Priority should be given to addressing these issues.
Potential for Food Safety Risk if not controlled.
Low food safety issue but relevant controls amy still be needed to comply with quality, legal or customer issues.

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Hazards
Type

Source

Likelihood

Impact

Risk

Risk Justification

Foreign matter

Occurrence improbable based on historical complaint data. Consideration given to raw milk that may be adulterated or
maliciously contaminated occurrence is improbable based on historic data.

Multiplication of pathogens and

spoilage organisms possible heat
stable toxin production.

Probable in milk, and if not controlled, a food safety hazard.

Residues and chemical

contamination

Occurrence occasional in milk, mainly due to antibiotics/feed/chemical taints, severity is minimal due to controls at
farm, however antibiotic residue could be critical in the long term. Packaging bought against specification and checked
visually for damage on receipt, historical complaint information does not identify problems. Organic Status of milk is
confirmed prior to unloading.

1D

Allergenic Material

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen advice on consumer
packaging

2A

Foreign matter

Occurrence improbable, possible contaminants could be due to defective tanker equipment or detergent residues e.g.
scale. Adulteration or malicious contamination occurrence improbable based on historic data. Milk is filtered through a 1
mm filter

Multiplication of pathogens and

spoilage organisms possible heat
stable toxin production.

Probable in milk, and if not controlled, a food safety hazard. Unlikely in packaging.

2C

Chemical contamination
including antibiotics harmful to
health

Occasional antibiotic/feed/chemical taint, severity is minimal due to controls at farm, however antibiotic residue could
affect the fermentation process and would not conform to Organic Standards

2D

Allergenic Material

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen advice on consumer
packaging

3A

Foreign matter

Occurrence improbable, possible contaminants could be due to defective equipment or detergent residues e.g. scale.
Adulteration or malicious contamination improbable based on historic data.

Multiplication of pathogens and

spoilage organisms possible heat
stable toxin production.

Probable in raw milk only, and if not controlled, a food safety hazard. Stored for 48 hours maximum. Can be used under
concession beyond this point.

3C

Residues and chemical

contamination

3D

Allergenic Material

4A

Foreign matter

Occurrence improbable, possible contaminants could be due to defective equipment or scale/burnt on milk. Adulteration
or malicious contamination improbable based on historic data.

Multiplication of pathogens and

spoilage organisms possible heat
stable toxin production.

Probable in milk, and if not controlled, a food safety hazard

Residues and chemical

contamination

4D

Allergenic Material

5A

Foreign matter

Occurrence improbable, possible contaminants could be due to defective equipment or scale residues. Adulteration or
malicious contamination improbable based on historic data.

Multiplication of pathogens and

spoilage organisms possible heat
stable toxin production.

Skim thermised, cooled and stored in insulated tanks. Target storage time less than 24 hours. Concession required for
storage time beyond this with a maximum of 60 hours. Product to be fully pasteurised if extended storage time required.

5C

Residues and chemical

contamination

5D

Allergenic Material

1A

1B

1C

2B

3B

4B

4C

5B

Supplier approval and

receipt. All Milk is sourced
from XXXX Cooperative.
Sugar, Whey Protein
Concentrate, Cream and
Skim Milk Powder are all
sourced from approved
suppliers.

Raw milk inspection and off

loading into Raw Milk Silo
X2 , Silo capacity 120,000
litres total

Raw milk storage

Processing (including pre

heating, separation, skim
undergoes Thermisation and
cooling, cream undergoes
pasteurisation, and cooling )

Storage of thermised cooled

skim

Historical data indicates limited likelihood of occurrence when tanker testing controls in place, with minimal risk from
cleaning chemicals. Final fresh water rinse.
Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen advice on consumer
packaging

Historical data indicates limited likelihood of occurrence, with minimal risk from cleaning chemicals. Final fresh water
rinse.
Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen advice on consumer
packaging

Historical data indicates limited likelihood of occurrence, with minimal risk from cleaning chemicals. Final fresh water
rinse.
Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen advice on consumer
packaging

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Hazards
Type

Source

Likelihood

Impact

Risk

Risk Justification

Foreign matter

Occurrence improbable, possible contaminants could be due to defective equipment, scale residues or from Skim Milk
Powder packaging. Adulteration or malicious contamination improbable based on historic data.

Multiplication of pathogens and

spoilage organisms possible heat
stable toxin production.

Product reconstituted using thermised skimmed milk and stored in insulated silo. Target storage time less than 24 hours.
Concession required for storage time beyond this with a maximum of 60 hours.

6C

Residues and chemical

contamination

Historical data indicates limited likelihood of occurrence, with minimal risk from cleaning chemicals. Final fresh water
rinse.

6D

Allergenic Material

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen advice on consumer
packaging

Foreign matter

Occurrence improbable, possible contaminants could be due to defective equipment or Ingredients. Ingredients
purchased via an approved supplier. Equipment is on Preventative and Planned maintenance system. Adulteration or
malicious contamination improbable based on historic data.

Multiplication of pathogens and

spoilage organisms possible heat
stable toxin production.

Blended product to be used within a target time of 24 hours, with a maximum time of 48 hours. Pasteurised from these
tanks.

Residues and chemical

contamination

Historical data indicates limited likelihood of occurrence, with minimal risk from cleaning chemicals. Final fresh water
rinse.

7D

Allergenic Material

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen advice on consumer
packaging

8A

Foreign matter

Occurrence improbable, possible contaminants could be due to defective equipment or scale/burnt on milk. Adulteration
or malicious contamination improbable based on historic data.

Multiplication of pathogens and

spoilage organisms possible heat
stable toxin production.

Probable in milk, and if not controlled, a food safety hazard

8C

Residues and chemical

contamination

8D

Allergenic Material

9A

Foreign matter

Occurrence improbable, possible contaminants could be due to defective equipment or scale/burnt on milk. Adulteration
or malicious contamination improbable based on historic data.

Survival & multiplication of pathogens and spoilage organisms with possible heat stable toxin production.

6A

6B

7A

7B

7C

8B

9B

Reconstitution of Skim Milk

Powder

Blending Operation
(includes blending of Raw
Milk / Skimmed Milk/
Cream reconstituted Skim
Milk Powder/ Whey Protein
Concentrate/Skim Milk
Concentrate/ organic sugar
as applicable) to desired fat
and protein level.

Heating and
Homogenisation

Thermal Treatment of
Yogurt Base

Survival & multiplication of

pathogens and spoilage
organisms possible heat stable
toxin production.
Residues and chemical
contamination

Historical data indicates limited likelihood of occurrence, with minimal risk from cleaning chemicals. Final fresh water
rinse.
Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen advice on consumer
packaging

Historical data indicates limited likelihood of occurrence, with minimal risk from cleaning chemicals. Final fresh water
rinse.
Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen advice on consumer
packaging

9C

9D

Allergenic Material

10A

Foreign matter

Occurrence improbable, possible contaminants could be due to defective equipment or scale residues. Adulteration or
malicious contamination improbable based on historic data. Inline filtration

Product heat treated and stored in insulated tanks. Therefore is not a food safety risk.

10B

Cooling to incubation
temperature. (Transfer to
inoculation Tanks)

Multiplication of pathogens and

spoilage organisms possible heat
stable toxin production.
Residues and chemical
contamination

Historical data indicates limited likelihood of occurrence, with minimal risk from cleaning chemicals. Final fresh water
rinse.
Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen advice on consumer
packaging

10C

10 D

Allergenic Material

11A

Foreign matter

Occurrence improbable, possible contaminants could be due to defective equipment or scale residues or starter packaging

Multiplication of pathogens and

spoilage organisms possible heat
stable toxin production.

Cleaning routines vary from fully automated to manual, controlled via Prerequisites. Possibility of product spoilage if
not carried out effectively.

11C

Residues and chemical

contamination

Historical data indicates limited likelihood of occurrence, with minimal risk from cleaning chemicals. Final fresh water
rinse.

11D

Allergenic Material

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen advice on consumer
packaging

11B

Inoculation of Yogurt Base

with Dairy Starter Culture.

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Hazards
Type

Source

Likelihood

Impact

Risk

Foreign matter

Multiplication of pathogens and

spoilage organisms possible heat
stable toxin production.

12C

Residues and chemical

contamination

12D

Allergenic Material

13A

Foreign matter

Occurrence improbable, possible contaminants could be due to defective equipment or scale residues. Ingredients bought
in from approved suppliers. Filtration in Place

Multiplication of pathogens and

spoilage organisms possible heat
stable toxin production.

Cleaning routines vary from fully automated to manual, controlled via Prerequisites. Possibility of product spoilage if
not carried out effectively.

13C

Residues and chemical

contamination

13D

Allergenic Material

14A

Occurrence occasional but with minimal impact, mainly packaging. Adulteration and malicious contamination
improbable based on historic data.
Cleaning routines include CIP and are controlled via pre-requisites.
Filler intervention historically does not indicate major contamination problems but could be responsible for spoilage
issues.

12A

12B

13B

Incubation of Yogurt Base

Pumping And Mixing

(ingredients and flavours as
applicable)

Foreign matter

Risk Justification
Occurrence improbable, possible contaminants could be due to opening lid to take sample for pH testing. Enclosed
system
Slow Vat procedure in place. Must reach a pH of 4.6 in a maximum of 15hours and Starter Rotation as required.
Potential Phage contamination controlled by fogging schedule.
Historical data indicates limited likelihood of occurrence, with minimal risk from cleaning chemicals.
Final fresh water rinse.
Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen advice on consumer
packaging

Historical data indicates limited likelihood of occurrence, with minimal risk from cleaning chemicals. Final Fresh Water
rinse.
Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen advice on consumer
packaging

Multiplication of pathogens and

spoilage organisms possible heat
stable toxin production.

14C

Residues and chemical

contamination

14D

Allergenic Material

Only sealed packs handled, any damaged packs removed.

Sealed packs subjected to temperature abuse could ferment / spoil, but not a safety issue, controlled to maintain shelf
life. .

14B

Pot Filling, Sealing and

Coding

15A

15B

Blast Chilling

15C

Foreign matter

Multiplication of pathogens and

spoilage organisms possible heat
stable toxin production.

Residues and chemical

contamination

Historical data indicates limited likelihood of occurrence, with minimal risk from cleaning chemicals. Final Fresh Water
rinse.
Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen advice on consumer
packaging

Limited risk from environmental cleaning as packs are sealed. All damaged packs removed.

15D

Allergenic Material

16A

Foreign matter

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen advice on consumer
packaging
Occurrence occasional, mainly packaging.

Multiplication of pathogens and

spoilage organisms possible heat
stable toxin production.

Minor risk as product processed but possible spoilage risk affecting shelf life quality.

3
1

3
1

9
1

Historical data indicates limited likelihood of occurrence, with minimal risk from cleaning chemicals
Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen advice on consumer
packaging
Occurrence improbable, possible contaminants could be due to defective equipment or scale residues.

16B

Sleeving of Multipack / Top

Hat Overlids

Residues and chemical

contamination
Allergenic Material
Foreign matter

16C

16D
17A

A
P

17B

Multiplication of pathogens and

spoilage organisms possible heat
stable toxin production.

Cleaning routines vary from fully automated to manual, controlled via Prerequisites. Possibility of product spoilage if
not carried out effectively.

17C

Residues and chemical

contamination

Historical data indicates limited likelihood of occurrence, with minimal risk from cleaning chemicals

17D

Allergenic Material

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen advice on consumer
packaging

Metal Detection

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Hazards
Type
P

Source
Foreign matter

Likelihood
1

Impact
1

Risk
1

Risk Justification
Only sealed packs handled, any damaged packs removed.

Multiplication of pathogens and

spoilage organisms possible heat
stable toxin production.

Sealed packs subjected to temperature abuse could spoil/ferment, but not a safety issue, controlled to maintain shelf life. .

18C

Residues and chemical

contamination

Limited risk from environmental cleaning as packs are sealed. All damaged packs removed.

18D

Allergenic Material

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen advice on consumer
packaging

18B
Cold Storage and dispatch

Verified By

Date Verified

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HACCP DECISION TREE

(Based on Codex Alimentarius)
Answer each question in sequence at each process step for each identified hazard

Q1. Do control measures exist?

Modify step, process or product
YES

NO
YES

Q1a. Is control necessary at this step for safety?

NO

Stop*
Q2. Is the step specifically designed to eliminate or reduce the likely
occurrence of a hazard to an acceptable level?
YES
NO

Q3.Could contamination with identified hazard(s) occur in excess of

acceptable level(s) or increase to unacceptable level(s)?

NO

YES

Stop*

Q4.Will a subsequent step eliminate the identified hazard(s) or reduce their

likely occurrence to an acceptable level?

YES

Stop*

* Stop and proceed with the next identified hazard(s)

NO

CRITICAL CONTROL
POINT

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HACCP Study for Stirred Yogurt NRC: Decision Tree

Process Step
No

Description

1A
1B
1C

Supplier approval and receipt. All Milk is

sourced from XXXX Cooperative

1D

Type

Hazards
Source

Risk

Q3

Purchased against Approved Supplier Specification

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen
advice on consumer packaging

Organic Status checked. Visually inspect prior to offloading. Tanker is rejected if milk is outside
specification. Filtered on offloading from tanker.

Multiplication of pathogens and spoilage organisms possible

heat stable toxin production.

Residues and chemical contamination

Purchased against Approved Supplier Specification.

Supplier Monitoring

2A

Foreign matter

2B

Multiplication of pathogens and spoilage organisms possible

heat stable toxin production.

Tanker is rejected if milk is outside specification.

M
Raw milk inspection and off loading into
Raw Milk Silo X2 , Silo capacity 120,000
litres total

Q4

Is it a CCP?

Q2

Allergenic Material

Decision Tree
Q1

Foreign matter

Control Measures
Visually inspect prior to / at offloading. Purchased to Approved Supplier Specification.

Chemical contamination including antibiotics harmful to health

Sampling and testing of incoming raw milk supplies to detect antibiotics. Tanker is rejected if milk is
outside specification.

2D

Allergenic Material

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen
advice on consumer packaging

3A

Foreign matter

Filters in CIP system, enclosed covered equipment

Multiplication of pathogens and spoilage organisms possible

heat stable toxin production.

Correct rotation of silos / temperature control. Routine testing of raw milk

3C

Residues and chemical contamination

Cleaning systems checked and verified.

3D

Allergenic Material

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen
advice on consumer packaging

4A

Foreign matter

Enclosed and covered equipment filtered/separated prior to heat treatment. Personal hygiene rules

Multiplication of pathogens and spoilage organisms possible

heat stable toxin production.

Heat treated at further stage as per legal and site requirements. Equipment validated minimum
annually.

Residues and chemical contamination

Cleaning systems checked and verified.

4D

Allergenic Material

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen
advice on consumer packaging

5A

Foreign matter

Enclosed and covered equipment filtered/separated prior to heat treatment. Personal hygiene rules

Multiplication of pathogens and spoilage organisms possible

heat stable toxin production.

Stock Rotation

5C

Residues and chemical contamination

Cleaning systems checked and verified.

5D

Allergenic Material

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen
advice on consumer packaging

6A

Foreign matter

Occurrence improbable, possible contaminants could be due to defective equipment or scale

residues. Adulteration or malicious contamination improbable based on historic data.

Multiplication of pathogens and spoilage organisms possible

heat stable toxin production.

Product reconstituted using thermised skimmed milk and stored in insulated silo. Target storage time
less than 24 hours. Concession required for storage time beyond this with a maximum of 60 hours.

Historical data indicates limited likelihood of occurrence, with minimal risk from cleaning chemicals.
Final fresh water rinse.

2C

3B

Raw milk storage

4B

4C

5B

Processing (including pre heating,

separation, skim Thermisation and
cooling of product )

Storage of thermised product (skim)

6B

Reconstitution of SMP
6C

Residues and chemical contamination

6D

Allergenic Material

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen
advice on consumer packaging

7A

Foreign matter

Enclosed equipment and packaging. Personal hygiene rules.

Multiplication of pathogens and spoilage organisms possible

heat stable toxin production.

Scheduled cleaning and equipment.

Monitoring of environment and personnel.
Intervention procedure for manual handling of equipment.

7C

Residues and chemical contamination

Validation of procedures annually. Monitoring of post cleaning hygiene checks

7D

Allergenic Material

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen
advice on consumer packaging

7B

CCP No

Blending Operation

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Description

Type
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Hazards
Source
Foreign matter

Risk
1

Control Measures

Decision Tree
Q1
Y

Q2
N

Q3
N

Q4

Visual inspection.

Is it a CCP?

Yogurt Base rejected if fails to meet specification, including temperature and stock rotation.

8C

Residues and chemical contamination

Cleaning controlled. Validation of equipment and procedures annually.

8D

Allergenic Material

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen
advice on consumer packaging

9A

Foreign matter

Enclosed and filtered CIP Systems.

9B

Multiplication of pathogens and spoilage organisms possible

heat stable toxin production.

Product Divert. Monitoring of Hygiene and Detergent concentrations

Residues and chemical contamination

Scheduled cleaning of equipment. Assured CIP cleaning methods. Verification of equipment.

8B

CCP No

Multiplication of pathogens and spoilage organisms possible

heat stable toxin production.

Heating and Homogenisation

9C

Thermal Treatment of Yogurt Base

9D

Allergenic Material

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen
advice on consumer packaging

10A

Foreign matter

Enclosed system

10B

Multiplication of pathogens and spoilage organisms possible

heat stable toxin production.

Chilled storage / distribution maintained to ensure shelf life requirements met. Prerequisite standards
apply.

Residues and chemical contamination

Scheduled cleaning of area to Prerequisite standard to prevent cross-contamination.

10D

Allergenic Material

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen
advice on consumer packaging

11A

Foreign matter

Enclosed and covered equipment. Coloured pots used. Personal hygiene rules. After incubation
product is filtered at the flow plate.

11B

Multiplication of pathogens and spoilage organisms possible

heat stable toxin production.

Hygiene rules. Sterilisation of pots. Personal hygiene rules

11C

Residues and chemical contamination

Scheduled cleaning of area to Prerequisite standard to prevent cross-contamination.

11D

Allergenic Material

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen
advice on consumer packaging

12A

Foreign matter

After incubation product is filtered at the flow plate to remove any potential contamination

Multiplication of pathogens and spoilage organisms possible

heat stable toxin production.

Correct rotation of tanks, time for pH to strike 4.4-4.6 in < 15 hours. Potential phage contamination
controlled by fogging and starter rotation as required.

12C

Residues and chemical contamination

Scheduled cleaning of area to Prerequisite standard to prevent cross-contamination.

12D

Allergenic Material

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen
advice on consumer packaging

13A

Foreign matter

Fruit preparations are purchased from an approved supplier. After adding to yogurt, hopper lids are
fitted.

13B

Multiplication of pathogens and spoilage organisms possible

heat stable toxin production.

Continues filling process. During breakdowns product will be potted off, quarantined until
Enterobacteriaceae results are obtained. For breakdowns of greater than 2 hours the hopper will be
emptied, product disposed and the hopper cleaned.

13C

Residues and chemical contamination

Scheduled cleaning of area to Prerequisite standard to prevent cross-contamination.

13D

Allergenic Material

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen
advice on consumer packaging

14A

Mixed yogurt is not filtered use to pieces of fruit in the yogurt. Metal pieces can be detected further
down the line

Multiplication of pathogens and spoilage organisms possible

heat stable toxin production.

Seal checks are carried out as per schedule. Date Code, Packaging Checks and Weight Control.

14C

Residues and chemical contamination

Scheduled cleaning of area to Prerequisite standard to prevent cross-contamination.

14D

Allergenic Material

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen
advice on consumer packaging

15A

Enclosed pots.

15B

Multiplication of pathogens and spoilage organisms possible

heat stable toxin production.

Pots chilled to <5C

Residues and chemical contamination

Scheduled cleaning of area to Prerequisite standard to prevent cross-contamination.

Allergenic Material

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen
advice on consumer packaging

10C

Cooling to incubation temperature.

(Transfer to Inoculation Tanks)

Inoculation of tanks

12B

Tank Incubation

Pumping And Mixing

14B

Foreign matter

Pot Filling, Sealing and Coding

15C

15D

Blast Chilling

Foreign matter

Document No:
Issue Date
Reason for amendment:

COM-HACCP-001
2/4/2010
General Update

Issue No:
Issued By:
Authorised By:

Page No:

Process Step
No
16A

Description

Type
P

7
ED
CM
12 of 13

Hazards
Source
Foreign matter

Risk
1

Control Measures

Decision Tree

Enclosed pots

Q1
Y

Q2
N

Q3
N

Q4

Is it a CCP?

Multiplication of pathogens and spoilage organisms possible

heat stable toxin production.

Pots removed from Blast Chiller for wrapping. Once wrapped placed in cold store

Residues and chemical contamination

Scheduled cleaning of area to Prerequisite standard to prevent cross-contamination.

16D

Allergenic Material

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen
advice on consumer packaging

17A

Foreign matter

Potential contamination from metal may be detected at this stage.

17B

Multiplication of pathogens and spoilage organisms possible

heat stable toxin production.

Pots removed from Blast Chiller for metal detection, during the wrapping operation. Once wrapped
placed in cold store

17C

Residues and chemical contamination

Scheduled cleaning of area to Prerequisite standard to prevent cross-contamination.

17 D

Allergenic Material

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen
advice on consumer packaging

16B

16C

Sleeving of Multipack/ Top Hat Overlids

Metal Detection

18A

Foreign matter

Enclosed pots

18B

Multiplication of pathogens and spoilage organisms possible

heat stable toxin production.

Cold stored until despatch. Despatched to distribution centres in a chilled vehicle.

Residues and chemical contamination

Scheduled cleaning of area to Prerequisite standard to prevent cross-contamination.

Allergenic Material

Milk and its derivatives are an allergen. However it cannot be managed out of the product. Allergen
advice on consumer packaging

18C

18 D

Verified By

Cold Storage and dispatch

Date Verified

CCP No

Document No:
Issue Date:
Reason for amendment:
Page No:

Process Step
No

Description

Raw milk inspection

and offloading

COM-HACCP-001 Issue No:

2/4/2010
Issued By:
General Update
Authorised By:
13 of 13

Control

Risk / Hazard

Control

CCP

Issue

Measure

Critical Limits
Target

CCP1

10

16

Thermal Treatment

Incubation of Yogurt
Base

Metal Detection

Verified By

CCP2

CCP3

CCP4

Survival & multiplication of

pathogens due to Slow
Fermentation

Non detection of metal

contamination in product

Work Instruction* /
Record

Corrective
Action

Check

Frequency

Checked By

None

Screen for
antibiotics to
industry test
standard

Each tanker /
compartment

Driver /
Operator / Lab
Staff

Lab Report
QAC-GEN-014

Reject tanker to meet

Animal By-Product
legislation requirements.

88C - 92C
(dependent on
equipment)

Past temp

Continuous
automated record /
calibrated yearly
by external agent

Process
Operative

Thermograph /
Operator's log
PRD-GEN-042

Recirculate plant until

satisfactory conditions
achieved / or shutdown /
stop production

In auto, record min

88C on rising and
falling

min 88C

None

Daily

Past operator

Thermograph /
Operator's log

Shut down plant / stop

production. Notify
Management

Preset holding time,

with a target of 330
seconds

330 seconds

minimum 330
seconds

Operator /
external

Operator's Log/
Calibration Record

If holding time is below

agreed setting, stop the plant
and report to Management.

Time and pH
Measurement

strike pH 4.4-4.6 < 9

hours

Chemical contamination by
antibiotics possibly detrimental Sampling and testing
to consumer health. Could
of incoming raw milk
affect Fermentation Process &
supplies
Contravenes Organic Status.

Survival of pathogens due to

under pasteurisation

Monitoring Procedure

Tolerance

Absent

Divert at 88C

7
ED
CM

Pasteurised as per
Dairy Hygiene Regs
2006 and site
standards

Test all pots through

metal detector

Date Verified

Flow Rate and / or Plant Startup and

measurement of
change overs/
flow rate by
annually by
external verification
external agent

pH 4.6 / Maximum pH and Temperature

15 hours
Checks

Every Tank

Lab

Lab Report
QAC-GEN-031

Report to QAM
immediately. Stop
production.

Full detection to
2.5mm Ferrous, 3.0
mm non-Ferrous and
3.5mm Stainless Steel

None

Metal Detector
Checks with Test
Pieces

Per pallet of
product

Despatch

Wrapping Log /
Lab Report
QAC-GEN-017

Product quarantined and rechecked.

Multipacks Full
detection of 3.5mm
Ferrous Test Piece

None

Metal Detector
Checks with Test
Pieces

Per pallet of
product

Despatch

Wrapping Log /
Lab Report

Product quarantined and rechecked.