1. Assess the Hazards in a Dairy Plant
a) Construct a flow diagram of each process in your dairy plant. The flow diagrams in Part II or
block diagrams can be used to illustrate each process.
b) The flow diagram(s) should give a clear and simple description of the steps in each process.
Include the actual equipment, procedures, and operating practices.
c) List all potential hazards associated with each step in the process. Consider as hazards only
those microbiological, chemical, and physical agents that could cause a public health risk.
Information provided in Part II and the Appendices will assist you in assessing potential
hazards.
d) List any preventive measures (PM) that may exist to control those potential hazards.
Preventive measures are those steps or controls in the process designed to eliminate or
control a hazard (i.e. pasteurization, hand dip sanitizing).
e) The potential hazards and preventive measures together identify possible CCPs.
2. Determine Critical Control Points (CCPs)
a) Once having identified a possible CCP (See Figure 1 - Page 7), four questions will
confirm whether or not a CCP exists. These questions are:
(i) Does a preventive measure exist?
(ii) Does this step eliminate or reduce the hazard to an acceptable level?
(iii) Could the hazard contaminate the product?
(iv) Is this preventive measure the last opportunity for eliminating the hazard?
Figure 1 (Page 7) illustrates how answers to each question will confirm the existence of
a CCP.
b) Mark each CCP on your flow diagram.
c) The CCPS identified in the schematics in Part II are explained in the accompanying
table. These will assist in the identification of CCPs in your dairy plant.
3. Establish Critical Limits for each CCP
a) For each CCP, the preventive measure must be fully defined.
b) Critical limits are a set of tolerances for each CCP.
c) Examples of Critical Limits
Critical Control Point Critical Limit
Refrigeration temperatures. 4°C
Minimum HTST pasteurization times/temperatures for milk. 16 seconds at 72°C
Response of a flow diversion valve on an HTST pasteurizer 1 second
Dairy Processing Plants (HACCP)
- 5 -
d) Strict adherence to tolerances is important in maintaining a HACCP program. Product safety
is not negotiable; there is no such thing as "almost risk free".
e) Tolerances may vary depending on processes in your plant.
f) For assistance in establishing critical limits, refer to the fourth column in the tables in Part
II.
4. Implement Procedures to Monitor CCP and Record Data
a) The CCP must be monitored on a regular basis to ensure that it is under control.
b) Examples of such monitoring can include:
(i) inspection of pasteurizer recording charts.
(ii) measurement of sanitizer levels.
(iii) observation of the hygiene of an operation or operator .
c) Records must be kept to ensure the CCPs are being monitored on a regular basis.
d) Several people in the dairy plant may be involved in monitoring CCPs and recording
data. As such, information regarding the HACCP program must be effectively
communicated. Everyone involved must understand its function and their role in its
implementation in order to be assured of its success.
e) The third column in the table in Part II under "Monitoring Frequency" provides a
timetable for monitoring CCPs. The timetable for monitoring CCPs may vary between
dairy plants.
5. Institute Corrective Action
a) In any HACCP program, a CCP may fail. As such, corrective action plans must be
included as a part of the program.
b) For each CCP, a specific corrective action must be in place in the event of a CCP
deviation from the critical limit tolerance. Action must include:
(i) Procedure for holding product pending completion of analysis to confirm product
safety.
(ii) Disposition of the product if necessary.
c) If a product cannot be proven safe, then it must be disposed of, or if possible, safely
reworked.
d) As well, the reasons for deviations must be found, documented, and corrected.
e) The fifth column under " Actions on Deviations" in each table of Part II lists appropriate
actions to take when CCP criteria are not met.
Dairy Processing Plants (HACCP)
- 6 -
6. Establish Record Keeping Systems to Document HACCP Plan
a) A single individual should be made responsible for ensuring all data is collected and
recorded. This individual must have authority to ensure:
(i) all data is collected
(ii) all data is centrally located and thus easy to retrieve
(iii) a record of all CCP deviations is kept, and, most importantly
(iv) appropriate action is taken when results deviate beyond the critical limits.
b) The record keeping system must be as simple as possible. A single binder for smaller
operations or a single filing cabinet for larger operations should be more than adequate.
7. Verify that the HACCP Program is Working
a) Most dairy plants are now performing regular quality control testing of their finished
products. Results from quality control tests can often indicate that a HACCP program is
not performing as required. In such cases, the program must be reviewed to ensure:
(i) the present HACCP program is being followed
(ii) all hazards were identified in the initial HACCP program
b) Other methods to verify the HACCP program is working include:
(i) Close monitoring of consumer complaints.
(ii) Verification inspections: unannounced equipment inspections.
(iii) Regular review of the current HACCP program. Have processes, procedures, or
formulations changed since the initial HACCP program was implemented?
(iv) Random sample collection and testing (separate from regular QC/QA testing
protocol).
c) It is particularly important to ensure the HACCP program is working when it is first
installed. As well, verification procedures must be made a priority when any changes in
processing procedures or formulations are made.
1. Assess the Hazards in a Dairy Plant
a) Construct a flow diagram of each process in your dairy plant. The flow diagrams in Part II or
block diagrams can be used to illustrate each process.
b) The flow diagram(s) should give a clear and simple description of the steps in each process.
Include the actual equipment, procedures, and operating practices.
c) List all potential hazards associated with each step in the process. Consider as hazards only
those microbiological, chemical, and physical agents that could cause a public health risk.
Information provided in Part II and the Appendices will assist you in assessing potential
hazards.
d) List any preventive measures (PM) that may exist to control those potential hazards.
Preventive measures are those steps or controls in the process designed to eliminate or
control a hazard (i.e. pasteurization, hand dip sanitizing).
e) The potential hazards and preventive measures together identify possible CCPs.
2. Determine Critical Control Points (CCPs)
a) Once having identified a possible CCP (See Figure 1 - Page 7), four questions will
confirm whether or not a CCP exists. These questions are:
(i) Does a preventive measure exist?
(ii) Does this step eliminate or reduce the hazard to an acceptable level?
(iii) Could the hazard contaminate the product?
(iv) Is this preventive measure the last opportunity for eliminating the hazard?
Figure 1 (Page 7) illustrates how answers to each question will confirm the existence of
a CCP.
b) Mark each CCP on your flow diagram.
c) The CCPS identified in the schematics in Part II are explained in the accompanying
table. These will assist in the identification of CCPs in your dairy plant.
3. Establish Critical Limits for each CCP
a) For each CCP, the preventive measure must be fully defined.
b) Critical limits are a set of tolerances for each CCP.
c) Examples of Critical Limits
Critical Control Point Critical Limit
Refrigeration temperatures. 4°C
Minimum HTST pasteurization times/temperatures for milk. 16 seconds at 72°C
Response of a flow diversion valve on an HTST pasteurizer 1 second
Dairy Processing Plants (HACCP)
- 5 -
d) Strict adherence to tolerances is important in maintaining a HACCP program. Product safety
is not negotiable; there is no such thing as "almost risk free".
e) Tolerances may vary depending on processes in your plant.
f) For assistance in establishing critical limits, refer to the fourth column in the tables in Part
II.
4. Implement Procedures to Monitor CCP and Record Data
a) The CCP must be monitored on a regular basis to ensure that it is under control.
b) Examples of such monitoring can include:
(i) inspection of pasteurizer recording charts.
(ii) measurement of sanitizer levels.
(iii) observation of the hygiene of an operation or operator .
c) Records must be kept to ensure the CCPs are being monitored on a regular basis.
d) Several people in the dairy plant may be involved in monitoring CCPs and recording
data. As such, information regarding the HACCP program must be effectively
communicated. Everyone involved must understand its function and their role in its
implementation in order to be assured of its success.
e) The third column in the table in Part II under "Monitoring Frequency" provides a
timetable for monitoring CCPs. The timetable for monitoring CCPs may vary between
dairy plants.
5. Institute Corrective Action
a) In any HACCP program, a CCP may fail. As such, corrective action plans must be
included as a part of the program.
b) For each CCP, a specific corrective action must be in place in the event of a CCP
deviation from the critical limit tolerance. Action must include:
(i) Procedure for holding product pending completion of analysis to confirm product
safety.
(ii) Disposition of the product if necessary.
c) If a product cannot be proven safe, then it must be disposed of, or if possible, safely
reworked.
d) As well, the reasons for deviations must be found, documented, and corrected.
e) The fifth column under " Actions on Deviations" in each table of Part II lists appropriate
actions to take when CCP criteria are not met.
Dairy Processing Plants (HACCP)
- 6 -
6. Establish Record Keeping Systems to Document HACCP Plan
a) A single individual should be made responsible for ensuring all data is collected and
recorded. This individual must have authority to ensure:
(i) all data is collected
(ii) all data is centrally located and thus easy to retrieve
(iii) a record of all CCP deviations is kept, and, most importantly
(iv) appropriate action is taken when results deviate beyond the critical limits.
b) The record keeping system must be as simple as possible. A single binder for smaller
operations or a single filing cabinet for larger operations should be more than adequate.
7. Verify that the HACCP Program is Working
a) Most dairy plants are now performing regular quality control testing of their finished
products. Results from quality control tests can often indicate that a HACCP program is
not performing as required. In such cases, the program must be reviewed to ensure:
(i) the present HACCP program is being followed
(ii) all hazards were identified in the initial HACCP program
b) Other methods to verify the HACCP program is working include:
(i) Close monitoring of consumer complaints.
(ii) Verification inspections: unannounced equipment inspections.
(iii) Regular review of the current HACCP program. Have processes, procedures, or
formulations changed since the initial HACCP program was implemented?
(iv) Random sample collection and testing (separate from regular QC/QA testing
protocol).
c) It is particularly important to ensure the HACCP program is working when it is first
installed. As well, verification procedures must be made a priority when any changes in
processing procedures or formulations are made.
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