HACCP implementation on cheddar cheese
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This document outlines the HACCP implementation plan for a cheddar cheese production process. It begins with an overview of cheddar cheese and describes the process flow chart. It then identifies potential biological, chemical and physical hazards at each process step. For key steps identified as critical control points, it lists preventative measures, critical limits, monitoring procedures, frequency and corrective actions. The 11 process steps covered are raw milk receiving, pasteurization, ripening, setting, scalding, milling, salting, curing, cutting, packaging and storage/distribution. References are provided to support the HACCP analysis.
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HACCP implementation on cheddar cheese
- 1. HACCP Implementation on Process Line of Cheddar Cheese Submitted BY: Muhammad Saad Haleem (NIFSAT) UNIVERSITY OF AGRICULTURE,FAISALABAD
- 2. Cheddar Cheese • Natural cheese: sliced, diced or grated • Processed cheese products • Dried cheese products • Enzyme-modified cheese products • Slightly crumbly texture (Fox. et al., 2017)
- 3. Process Flow Chart Raw Milk Receiving Pasteurization (72 ⁰C,16 sec) Add Rennet & Starter SettingScalding Draining, Milling, Salting & Pressing Curing Cutting & Retail Packaging Storing & Distribution
- 4. Hazard Analysis Chart Process steps Biological Hazard Chemical Hazard Physical Hazard Farm Microbes Antibiotic residues Foreign objects Collection Center Microbes Antimicrobial residues Foreign objects Receiving Microbes Antibiotic residues Foreign objects Chilling - Antibiotic residues Physical contamination Pre-Heating Microbes Antibiotic residues Unhygienic conditions
- 5. Process Steps Preventative Measures Critical Limits Monitoring Procedure Monitoring Frequency Corrective Action Raw & packaging material CCP # 1 Qualified starter & rennet supply, Qualified cryvoac supply, Sieves, screens & filters No unqualifie d material be used Apply supply quality assurance, Visual inspection Each supply Change supplier Reject lot Physical Hazard Stones, husk, hair, glass, metal, plastic fragments, wood chips Biological Hazard Insects, pest, antibiotic residues, microbes ( Salmonella spp, Listeria monocytogenes, E.coli, Campylobacter spp, Brucella melitensis, Mycobacterium bovis, Staphylococcus enterotoxins) aflatoxins, veterinary drugs. Chemical Hazard Formalin, urea, detergents, boric acid, ammonium sulphate, sugar, hydrogen peroxide, melamine, salicylic acid, benzoic acid, NaCl.
- 6. Process Steps Preventative Measures Critical Limits Monitoring Procedure Monitoring Frequency Corrective Action Pasteurizer checks: -Check time & temperature limit -check the flow diversion -Low initial microbial load -X-ray inspection Temperatur e set at 72ºC, Time set at 16 sec Check thermometer and time, Check equipment is properly running , Supervisor managing, Record keeping After every 30 min Routinely Adjust the temperature & time, Calibrate the equipment, Call the engineer to repair Physical Hazard Stones, husk, hair, glass, metal, plastic fragments, wood chips Biological Hazard Bacillus spp, Clostridium spp, Coxiella burenetti, spores & thermoduric bacteria. Chemical Hazard Cleaning disinfectant: sodium hypochlorite, hydrogen peroxide, iodine, isothiazolinones, ozone, peracetic acid, phenolics & surfactants.
- 7. Process Step Preventive Measure Critical Limits Monitoring Procedure Monitoring Frequency Corrective Action Rippening CCP #3 Agitate properly, Avoid over- flow of culture, Avoid using over-aged culture Starter: -0.51% milk Temperatur e 31C, -Annatto 30- 200ml/100 0ml of milk -Rennet 15- 25ml/100lit of Milk Check the additional rate of the starter and rennet & pH, Check the rate of the agitator, Record keeping, Check expiry of culture to be used Check pH after 30 min Applying more testing on pH, Use active starter culture, Calibrate pH meter, Adjust agitate rate, Operator training Physical Hazard Stones, husk, hair, nut, bolt Biological Hazard Bacillus spp, Clostridium spp, Coxiella burenetti, spores & thermoduric bacteria Chemical Hazard Cleaning disinfectant: sodium hypochlorite, hydrogen peroxide, iodine, isothiazolinones, ozone, peracetic acid, phenolics & surfactants
- 8. Process Step Preventive Measure Critical Limits Monitoring Procedure Monitoring Frequency Corrective Action Proper time setting and recording Take the stirring tools out of the tank Time is set at 30min Tools prevent coagulation Check the time and the stirring tools Record keeping Ater 30 min Reject product Operator training Physical Hazard Stones, husk, hair, nut, bolt Biological Hazard Bacillus spp, Clostridium spp, Coxiella burenetti, spores & thermoduric bacteria Chemical Hazard Cleaning disinfectant: sodium hypochlorite, hydrogen peroxide, iodine, isothiazolinones, ozone, peracetic acid, phenolics & surfactants Setting CCP #4
- 9. Process Step Preventive Measure Critical Limits Monitoring Procedure Monitoring Frequency Corrective Action Proper time setting and recording Take the stirring tools out of the tank Time is set at 30min Tools prevent coagulation Check the time and the stirring tools Record keeping Each batch Reject product Operator training Physical Hazard Stones, husk, hair, nut, bolt Biological Hazard Bacillus spp, Clostridium spp, Coxiella burenetti, spores & thermoduric bacteria Chemical Hazard Cleaning disinfectant: sodium hypochlorite, hydrogen peroxide, iodine, isothiazolinones, ozone, peracetic acid, phenolics & surfactants
- 10. Process Step Preventive Measure Critical Limits Monitoring Procedure Monitoring Frequency Corrective Action Scalding CCP #6 Proper time & temperature setting Temperature is set at 38ºC, scalding for 30min, Stirring for 20min Check the temperature and the time, Record keeping, Check fine cutting of coagulum into cubes Carried out after every 15 minutes Adjust the heater to change temperature Operator training Physical Hazard Stones, husk, hair, nut, bolt, corrosive equipments,glass,metal and plastic fragments. Biological Hazard Bacillus spp, Clostridium spp, Coxiella burenetti, spores & thermoduric bacteria. Chemical Hazard Cleaning disinfectant: sodium hypochlorite, hydrogen peroxide, iodine, isothiazolinones, ozone, peracetic acid, phenolics & surfactants.
- 11. Process Step Preventive Measure Critical Limits Monitoring Procedure Monitoring Frequency Corrective Action Milling CCP #7 More cheddaring time, Control the pH, Use of an active starter, Correct addition pH is measured at 5.2-5.4 Consistently monitor pH during Cheddaring, Supervisor’s managing, Record keeping Each batch Operator training Reject product applying more testing on pH Physical Hazard corrosive equipments,glass,metal and plastic fragments. Biological Hazard Bacillus spp, Clostridium spp, Coxiella burenetti, spores & thermoduric bacteria. Chemical Hazard Cleaning disinfectant: sodium hypochlorite, hydrogen peroxide, iodine, isothiazolinones, ozone, peracetic acid, phenolics & surfactants
- 12. Process Step Preventive measures Critical Limits Monitoring Procedure Monitoring frequency Corrective action Salting CCP#8 Correct level of salt, Correct mixing during salting Salt 1.5-2% Observe hardening & shrinking of curd, Check undesirable fermentation Record keeping & testing Each batch Incorrectly salted cured must not be allowed to progress Physical Hazard corrosive equipment Biological Hazard Bacillus spp, Clostridium spp, Coxiella burenetti, spores & thermoduric bacteria. Chemical Hazard Cleaning disinfectant: sodium hypochlorite, hydrogen peroxide, iodine, isothiazolinones, ozone, peracetic acid, phenolics & surfactants.
- 13. Process Step Preventive measures Critical Limits Monitoring Procedure Monitoring frequency Corrective action Curing CCP#9 Maintain curing temperature, Check humidity 10-16C temperature, RH of 50%, Time period of 2-4 months Observe change in chemical, physical & bacteriologic al properties Check after each day Curing room should be isolated to avoid any exterior contaminati on, Avoid cross contaminati on inside curing room Physical Hazard corrosive equipment Biological Hazard Bacillus spp, Clostridium spp, Coxiella burenetti, spores & thermoduric bacteria Chemical Hazard Cleaning disinfectant: sodium hypochlorite, hydrogen peroxide, iodine, isothiazolinones, ozone, peracetic acid, phenolics & surfactants
- 14. Process Step Preventive measures Critical Limits Monitoring Procedure Monitoring frequency Corrective action Cutting & retail packaging CCP#10 sievers, screens,filters Use specific size of cutters Low level shocks,less impact with other packages Visual inspection of packages and packing material. Every 3 Hour Build proper structural frame Cabinet for placement of pallets in warehouse Physical Hazard Tempetature+Humidity Biological Hazard Bacillus spp, Clostridium spp, Coxiella burenetti, spors & thermoduric bacteria. Chemical Hazard Cleaning disinfectant: sodium hypochlorite, hydrogen peroxide, iodine, isothiazolinones, ozone, peracetic acid, phenolics & surfactants.
- 15. Process Step Preventive measures Critical Limits Monitoring Procedure Monitoring frequency Corrective action Storing & Distribution CCP#11 Maintain refrigeration temperature, Control Humidity, Cooling facility in carrier vehicle Temperature 4 C Record keeping, Documentatio n Check after every 60 min Avoid fluctuations during cold storage Physical Hazard Falling shocks,vibration,unsuitable temperature, humidity Biological Hazard Pseudomonas. Chemical Hazard Cleaning disinfectant: sodium hypochlorite, hydrogen peroxide, iodine, isothiazolinones, ozone, peracetic acid, phenolics & surfactants.
- 16. Reference • Fox P.F., T.M. Cogan and T.P. Guinee. 2017. Factors That Affect the Quality of Cheese. 9th Ed. Food Research Centre, Moorepark, Fermoy, Co. Cork, Ireland. 617-625. • Baraka A. 2019. Implementation of HACCP and ISO 22000- 2005 system for white cheese line. Al-Azhar University-Gaza. 29-46. • Asselt E.V., Marvin H.J.P., Van der Fels-Klerx H.J. 2016. Overview of food safety hazards in the European dairy supply chain. 16th Ed. University of Agriculture, Faislabad. 59-75. • Johnson M.E. 2017. A 100-Year Review: Cheese production and quality, Journal of Dairy Science. 100th Ed. American Dairy Science Association (ADSA). 9952-9965 • Carrascosa C., Sanjuan E. 2016. Identification of the risk factors asspociated with cheese production to implement the hazard analysis and critical control points (HACCP) system on cheese farms. 99th Ed. American Dairy Science Association (ADSA). 2606-2616.