The document provides an overview of Mother Dairy's efforts to implement international food safety standards and hygienic design practices. It discusses the increasing issue of foodborne illnesses in India and examples of safety incidents related to engineering issues. It then summarizes Mother Dairy's work to harmonize their management system with international references, and highlights case studies of implementing best practices for key processes like pasteurization, homogenization, and cleaning-in-place. This includes changes to meet international requirements for hygienic design, process control, and elimination of risks like cross-contamination.

1. Slide No. : 1
Date : 02 Dec 15 Presented By : Mother Dairy
Principles of Hygienic Equipment Design :
Dairy Case Study
Contents …
• Four Pillars for Safe Food
• Foodborne Outbreaks & Deaths in India - 2008-15
• Examples of Food Safety Incidents due to Hygienic Engineering issue
• Microbiological Specs India Vs. Other Countries
• Need for looking at International Standards
• Food Safety Maturity Continuum @ Mother Dairy……
• Case Study on International Best Practices Implementation at Mother Dairy
– CIP
– Pasteurization
– Homogenization
– Filling
– WTP
• Food Safety Risk Elimination
Th ough I ple e tatio of I te atio al Re ui e e ts ….

2. Slide No. : 2
Date : 02 Dec 15 Presented By : Mother Dairy
Four Pillars for Safe Food
As per Technical papers & case studies, most common reason for “Unsafe Food” is
inappropriate “Food Engineering” Practices (Globally as well as in India)

3. Slide No. : 3
Date : 02 Dec 15 Presented By : Mother Dairy
Source: http://www.idsp.nic.in
2008 2009 2010 2011 2012 2013 2014
2015(Till 21
Nov'2015)
No. of Outbreaks 553 799 990 1675 1584 1964 1585 1667
Death 50 120 95 77 1108 901 810 2636
553
799
990
1675
1584
1964
1585
1667
50 120 95 77
1108
901
810
2636
0
500
1000
1500
2000
2500
3000
0
500
1000
1500
2000
NO
Of
Deaths
No.
Of
Outbreaks
Geometric increase in number of Food Borne Cases
from as well as deaths in India
Integrated Disease Surveillance Project (IDSP), launched by UMoH&FW, India in Nov 2004
Number of outbreaks as well as Number of Deaths due to Food Borne Cases are on raise

4. Slide No. : 4
Date : 02 Dec 15 Presented By : Mother Dairy
Front View Back View
Un-even
Inaccessible area
Hygienic Design Issues - Few Examples
Key Food processing equipments, supplied to Industry were found with
such Hygienic Design issues

5. Slide No. : 5
Date : 02 Dec 15 Presented By : Mother Dairy
Hygienic Design Issues - Few Examples
Framework Design issue
with Inaccessible area
Smooth and accessible
area
Key Food processing equipments, supplied to Industry were found with
such Hygienic Design issues

6. Slide No. : 6
Date : 02 Dec 15 Presented By : Mother Dairy
Few examples of Food Safety Incidents due to
failures to Hygienic Engineering e ui e e ts …
The problem was traced to bacteria on
the production line of Snow Brand's
Osaku factory that processed low-fat milk.
As events played out, it transpired that
over 15,000 people had been affected.
The bacteria concerned was
staphylococcus aureus, and it was located
in a valve which, although it should
have been cleaned regularly, had not
been.
Inspections of the plant condemned
hygiene standards as being appalling.
SNOW RECALL – JAPAN
• The No.1 dairy Brand in Japan
• Business: $12 billion dollars in 2000
Source : http://www.mallenbaker.net/csr/crisis04.html Source : http://www.foodqualitynews.com/Food-Outbreaks/Lye-contaminated-milk-recalled-in-latest-blow-to-Chinese-dairy-industr

7. Slide No. : 7
Date : 02 Dec 15 Presented By : Mother Dairy
International Standards on Hygienic Design & Process Controls
Harmonization into Mother Dairy Management System (MDMS)
R
 Mother Dairy Management System is developed incorporating
various international references to address Quality & Food
Safety Requirements
 Process Innovations, Cross Contamination Controls as well as
other key Food Safety requirements are addressed
appropriately

8. Slide No. : 8
Date : 02 Dec 15 Presented By : Mother Dairy
Pasteurized Milk Microbiological Specification –
Comparison Table Different Countries
/g
M
M
M
M /gram

9. Slide No. : 9
Date : 02 Dec 15 Presented By : Mother Dairy
Trigger for Looking at “International Standards”
Yet to have Hygienic Equipment Design Standards in India for Milk & Liquid
Food Processing
 To demand equipment, meeting Hygienic Design Aspects, from Suppliers
 Stringent Microbiological Requirements by Food Safety Standards Authority of
India (FSSAI) –- Inline with International references
• Market Competiveness
• Proven Requirements – Hence “No Need to reinvent the Wheels”
• Brand Protection from Recall / Withdrawal Situations
• To minimize “Reprocessing / Rejections” due to process failures

10. Slide No. : 10
Date : 02 Dec 15 Presented By : Mother Dairy
Food Safety Maturity Continuum……
Through Strengthening Strictness of Control Measures
Food Safety Hazard
Identification
Stage
Control
Measures
Auto Detection & Manual Control
(Moderate Degree of Strictness of
Controlling a Hazard)
Manual Detection & Manual
Control
(Low Degree of Strictness of
Controlling a Hazard)
“Fail Safe” System
Auto Detection & Auto Control
(High Degree of Strictness of
Controlling a Hazard)
Based on the international requirement s....
Food Safety Hazards are newly identified & Control Measures are incorporated
 Ele ati g Deg ee of “t i t ess of Cu e t Le el to o steps a o e
Low Degree to Moderate Degree /
High Degree to Fail Safe

11. Slide No. : 11
Date : 02 Dec 15 Presented By : Mother Dairy
Hygienic Design for Effective Pasteurization of Milk ….
Majority of our own and 3P plants are upgraded to process controls as per international standards

12. Slide No. : 12
Date : 02 Dec 15 Presented By : Mother Dairy
Pasteurized
Product
Raw
Produc
t
Regeneration Zones
Cross Contamination Possibilities of Pasteurized Milk &
Prevention by Hygienic Design
Cross
Contamination
Majority of our own and 3P plants are upgraded to process controls as per international standards

13. Slide No. : 13
Date : 02 Dec 15 Presented By : Mother Dairy
Key Food Safety Requirements of Pasteurization
To have effective Pasteurization Milk / Liquid Foods

14. Slide No. : 14
Date : 02 Dec 15 Presented By : Mother Dairy
Comparison of Key Food Safety Requirements of Pasteurization
To Prevent Cross Contaminations during Pasteurization Liquid Foods

15. Slide No. : 15
Date : 02 Dec 15 Presented By : Mother Dairy
Hygienic Engineering Requirements Comparison Matrix
To Assure Food Safety During CIP

16. Slide No. : 16
Date : 02 Dec 15 Presented By : Mother Dairy
Hygienic Engineering Requirements Comparison Matrix
To Assure Food Safety During CIP

17. Slide No. : 17
Date : 02 Dec 15 Presented By : Mother Dairy
Pasteurizer Holding Loop Slope….
Why ? How ? Reference Specification
 To attain the minimum
holding time it is
critical that the design
of the holding tube
prohibits air from
being incorporated
into the system.
 Air in the system will
allow individual milk
particles to move
faster through the
holding tubes,
thereby reducing the
holding time
To preclude air
entrapment and
ensure uniform
product flow,
Holding tubes
should have
upward slope
 Provide Holding
Tubes slope 2.1
cm per meter ) from
the lowest point of
the holding tube to
the flow diversion
device.
 Connect the
Pasteurizer PHE
Heating Zone
outlet to the
bottom of the
Holding Loop so
as to have
upward flow.
 3A
USFDA – PMO
 EHEDG
 Canadian
Food
Inspection
Agency
 Other Food
Industry
Specs
Upward Slope from
the lowest point of
the holding tube to
the flow diversion
device
 2.1 cm per meter
or
0.25 inch per feet

18. Slide No. : 18
Date : 02 Dec 15 Presented By : Mother Dairy
Holding Coil Upward Slope Requirement in
Pasteurization & Sterilization of Liquid Foods

19. Slide No. : 19
Date : 02 Dec 15 Presented By : Mother Dairy
Holding Coil Drawing With & Without Continuous
Upward Slope min of 2.1 cm / meter

20. Slide No. : 20
Date : 02 Dec 15 Presented By : Mother Dairy
Holding Coil Drawing with Continuous
Upward Slope min of 2.1 cm / meter
The holding tube shall be arranged
to have a continuously upward
slope in the direction of flow of not
less than 2.1 centimeters per meter
(0.25 inches per foot).

21. Slide No. : 21
Date : 02 Dec 15 Presented By : Mother Dairy
Pasteurisation ….
Time & Temperature Control
• FDV Position : Holding Tube Outlet
• Temperature Sensor Position :
– Holding Tube Outlet, prior to FDV
– To take of Respo se Ti e of the te pe atu e se so fo
complete FDV activation
• Adequate distance to be provided between Temperature
Sensor Position & FDV
Holding Coil
International Ref :
• USFDA PMO,
• 3A
• AS 3993 : 2003
• Canadian Food Inspection Agency
• University of Guelph

22. Slide No. : 22
Date : 02 Dec 15 Presented By : Mother Dairy

23. Slide No. : 23
Date : 02 Dec 15 Presented By : Mother Dairy

24. Slide No. : 24
Date : 02 Dec 15 Presented By : Mother Dairy
Strengthening Pasteurization Controls with Two
Temperature Sensors (even in Semi auto Dairy Units)
 Temperature Sensor Failures Challenges
 As per EHEDG, FDV shall be controlled by more than 1 Sensor
 Forwards the milk / liquid food post achieving the right temperature in both
the sensors
 Implemented in Delhi NCR Plants contributing to about 80% Poly Pack Milk Volu e…

25. Slide No. : 25
Date : 02 Dec 15 Presented By : Mother Dairy
Preventing Raw Product Siphonage into
Pasteurized Product Line

26. Slide No. : 26
Date : 02 Dec 15 Presented By : Mother Dairy
Raw Product Siphonage : Balance Tank Design
Raw Milk Siphonage
Damaged FDV
Seat “O” Ring
Damaged
FDV Seat
“O” Ring

27. Slide No. : 27
Date : 02 Dec 15 Presented By : Mother Dairy
“ipho age of Ra Milk i ase O Ri g Failu e
“O” Ring Failure
Balance
Tank
Chilling
Zone
Heating
Zone
Homogenizer
Clarifier
Double Seat Mix-proof
Valve as Heating FDV
Holding Tube
Cooling FDV
Vacuum
Breaker “OFF”
Back Pressure
Valve
REG Bypass Valves
are “Closed”
Timing
Pump
Feed
Pump
REG - 1 REG - 2

28. Slide No. : 28
Date : 02 Dec 15 Presented By : Mother Dairy
Divert Line Connection to Balance Tank
 

29. Slide No. : 29
Date : 02 Dec 15 Presented By : Mother Dairy
Balance Tank Design to prevent Raw Milk
Siphonage


30. Slide No. : 30
Date : 02 Dec 15 Presented By : Mother Dairy
Prevention of Unacceptable re-infection of Pasteurized
Product – FDV with Double Seat Configuration

31. Slide No. : 31
Date : 02 Dec 15 Presented By : Mother Dairy
Single Seat FDV Design & limitations
FDV – Seat
“O” Rings
FDV – Seat
“O” Rings
FDV – Teflon
Gasket
Damaged FDV
Seat “O” Ring
Damaged FDV
Seat “O” Ring

32. Slide No. : 32
Date : 02 Dec 15 Presented By : Mother Dairy
Option # 1 : Primary & Secondary Seat Valve Set Up
for FDV Operation

33. Slide No. : 33
Date : 02 Dec 15 Presented By : Mother Dairy
Prevention of Unacceptable Re-infection of
Pasteurized Product – FDV with Double Seat Configuration
 The Mix proof valve is a completely Hygienic Double Seat Valve
 Simultaneous processes in the two bodies of the valve by providing interface
between the two fluids
 Thus, preventing the possibility of product contamination
Leakage from Upper
chamber through Leak Path
during one of the Seal
Failure
Water hammer during Process Balanced Mix-proof Valve

34. Slide No. : 34
Date : 02 Dec 15 Presented By : Mother Dairy
Post Pasteurization
Contamination Control
• Why ?
– Pasteurized Product is separated with the medium by the plates having
thickness 0.6 mm
– Microbes are in the medium (Raw Product / Cooling Medium)
– To Avoid cross Contamination of Pasteurized Product from raw product &
cooling medium
 Maintain Positive Pressure in the Pasteurized Product Side
 Install Booster Pump, Back Pressure Valve & Pressure Monitoring Devices
Pasteurized
Product
Raw
Product
Regeneration Zones
Pasteurized
Product Cooling
Medium
Cooling Zones

35. Slide No. : 35
Date : 02 Dec 15 Presented By : Mother Dairy
Pasteurizer Layout

36. Slide No. : 36
Date : 02 Dec 15 Presented By : Mother Dairy
• Maintaining Positive
Pressure in Pasteurized
Milk Side
– Equipped with booster pump
– Equipped with back pressure
valve
– Equipped with sanitary type
pressure gauges
– Raw Milk Inlet pressure is
generally about 2.5 Bar & IBT
pressure is about 3 bar
– If the Pasteurized milk pressure
in the cooling PHE outlet falls
below 3 bar, then alarm should
be activated & system should get
shut off with in next 1 min
Positive Pressure in Pasteurized Milk side –
Semi Auto Units

37. Slide No. : 37
Date : 02 Dec 15 Presented By : Mother Dairy
RECUPERATION
TANK
HOT WATER
TANK
850C
HOT
CAUSTIC LYE
TANK
60°-770C
1.0-1.5%
SUPPLY RETURN
A
B
D
T
S
F
R
E
S
H
W
A
T
E
R
CIP Kitchen Schematic - Tank Orientation
Generally observed at liquid food industries ….
PHE-A
PHE-B
PUMP-A
@ 20M3/hr
PUMP-B
@ 20M3/hr
A . CIP Circuit 1
B . CIP Circuit 2
W .Treated Water Inlet, D . Drain,
F . Flow Meter, S . Steam Inlet, T . Condensate Outlet
F
Food Safety Hazards are,
• Cross Contamination during Final Rinse step, since fresh water pass through the pipeline, where in Recup Water Flow
• Cross Contamination during Final Rinse step, in case of Valve failures in Caustic / Acid / Recup Tanks
Food Safety Hazards are,
• Absence of Cross Contamination controls, during Final Rinse step, while fresh water pass through the pipeline , where in
Recup Water has flown
• Cross Contamination during Final Rinse step, in case of Valve failures in Caustic / Acid / Recup Tanks

38. Slide No. : 38
Date : 02 Dec 15 Presented By : Mother Dairy
Cross Contamination Controls in CIP System
due to Valve Failures in the Tanks

39. Slide No. : 39
Date : 02 Dec 15 Presented By : Mother Dairy
39
Option # 1 :
CIP Tank Connection with Safe Flow Valves
Equipped with two seals
In case of any seal
failure, leakage can be
detected

40. Slide No. : 40
Date : 02 Dec 15 Presented By : Mother Dairy
Safety Drain
valve System
Equipped with double valve
drain provision
In case of seal failure of any of
the valves, leakage can be
detected at the drain valve
Option # 2 :
CIP Tank Connection with Single Seat Valves

41. Slide No. : 41
Date : 02 Dec 15 Presented By : Mother Dairy
Required Turbulence Velocity for CIP
1,5 m/s
5T Strategy for Safe CIP – Time, Temp, Titer, Turbulence & Technology
Most important and highly neglected one is Turbulence

42. Slide No. : 42
Date : 02 Dec 15 Presented By : Mother Dairy
 CIP of CIP tanks Shall help to upkeep the CIP kitchen
CIP of CIP Ta ks ….

43. Slide No. : 43
Date : 02 Dec 15 Presented By : Mother Dairy
Hot Water Sanitation – Through Heat Recovery Tube

44. Slide No. : 44
Date : 02 Dec 15 Presented By : Mother Dairy
 Use of Fresh Hot Water for every CIP to prevent contaminants (Microbiological / Physical / Chemical)
during Hot Water Sanitation.
 Energy efficient system, as only the loop volume i.e. 800 to 1200 liters of hot water to be heated to
80°C – 90°C prior to Sanitation step.
 Since Fresh Hot Water is used for every CIP, it is not necessary to have Final Rinse step. Hence about 3,000 to
4,000 Liters of Fresh Water per CIP shall be saved.
 Final Rinse time is Nil / negligible Vs Traditional Design.
Heat Recovery Tube for Hot Water Sanitation :
Better Food Safety along with Optimizing Natural Resources

45. Slide No. : 45
Date : 02 Dec 15 Presented By : Mother Dairy
Effect of Dead Ends in CIP Supply & Return Lines…

46. Slide No. : 46
Date : 02 Dec 15 Presented By : Mother Dairy
CIP Supply & Return
Headers
Effect of Dead Ends in CIP Supply & Return Lines…

47. Slide No. : 47
Date : 02 Dec 15 Presented By : Mother Dairy
Homogenizer - Internal Recirculation Line
Hygienic Design

48. Slide No. : 48
Date : 02 Dec 15 Presented By : Mother Dairy
Homogenizer - Internal Recirculation Line
Hygienic Design

49. Slide No. : 49
Date : 02 Dec 15 Presented By : Mother Dairy
Type of Dead Ends and Actions Taken

50. Slide No. : 50
Date : 02 Dec 15 Presented By : Mother Dairy
Cleaning & Sanitation Time of Silos @ Mother Dairy
Before & After 6 Sigma Project
Improvements
29 min  PMST CIP time is reduced by 29 min / CIP
 Sigma Level 1.5 to 3.9
 Water Saving - 25 KL/Day
 Power Saving - 10 KWH / Day
 Steam Saving - 600 Kgs / Day
Improvements
28 min
 PMST CIP time is reduced by 28 min
 Sigma Level 1.2 to 2.8
 Water Saving - 20 KL/Day
 Power Saving -10 KWH /Day
 Steam Saving - 400 Kgs /Day

51. Slide No. : 51
Date : 02 Dec 15 Presented By : Mother Dairy
Designing Sand & Carbon Filters with Dead End
< 1D in Filter Feed Line & Back Wash Lines
Carbon Filter Design with Dead End: While Filt atio is ON
E
A
Insideflow
B C F
Rinse & BackwashDrain
D
Valves are in Ope Position :
While Filtration : A,Fand D are in Open position
While Rinsing : A,C andD are in Openposition
G
Freeboard 500MM
Water
Inlet
ManHole
AirVent
<1D
Leakage detection any of valves
B or C to avoid chlorinated
water by pass
Lively
Dead
End
Carbon Filter Design with Hygienic Design: While Filt atio is ON
E
A
Insideflow
B C F
Rinse & BackwashDrain
D
Valves are in Ope Position :
While Filtration : A,Fand D are in Open position
While Rinsing : A,C andD are in Openposition
G
Freeboard 500MM
Water
Inlet
ManHole
AirVent
<1D
Leakage detection any of valves
B or C to avoid chlorinated
water by pass
#1 #2
--

52. Slide No. : 52
Date : 02 Dec 15 Presented By : Mother Dairy
Mother Dairy Innovation Ce t e’s Re ie Pape s on Hygienic Design of Pasteurizer
were published by JHED, Europe , (EHEDG - Macedonia Region)
on May 13 & Nov 14
1st Review Paper – May 13
2nd Review Paper – Nov 14

53. Slide No. : 53
Date : 02 Dec 15 Presented By : Mother Dairy
Food “afety Risk Eli i atio ….
Fight with the Risk
Damage is likely
Control the Risk
Failure of Control
shall be Disastrous
Understand the Risk
Rule the Risk
Understanding the risk and adopting Fail “afe Control Measures though
Hygienic Engineering shall be, the best option for Risk Elimination

54. Slide No. : 54
Date : 02 Dec 15 Presented By : Mother Dairy
“u a y…
 Food safety excellence is achievable, through..
 Implementing Hygienic Engineering requirements in each
process to address the various newly Identified Control
Measures
 Adopting Food Safety Maturity Continuum Model - escalating
to Fail “afe
 Quality & Food Safety are hard to define, impossible to
measure, easy to recognize