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Keywords
Dairy industry, HACCP, control points
1. Introduction
Milk can show large quality differences, which milk processors, must take into account. Two types of criteria are used for paying by quality physio-chemical and bacteriological. Physio-chemical criteria usually relate to the fat and protein content, the basic rate of which per kilo of milk varies from one to another. Testing for better bacteriological quality could result in finding specific bacteria such as Coliforms, Staphylococcus, Listeria and Butyric spores. Similarly, the presence of antibiotics and the milk temperature during collecting can be used as quality criteria and for price reduction. In addition, the presence of chemical residues could alter the process of elaboration of derived fresh milk products. (Karakok 2007; Vilar 2011). Milk quality is all about prevention on each step of production. Quality control systems aimed the prevention of defects, rather than their detection. Quality control occurs at every step in the production, as a raw material on farm condition. Consumers, processors and regulatory agencies are increasingly interested in the safety and wholesomeness of milk resulting in increased emphasis on the farm management to insure the production of milk quality (Noordhuizen and Metz 2005). The consumer demands safe and wholesome dairy products that can be purchased without any doubt. For raw milk the term quality is extremely comprehensive. There is a quality pyramid based for dairy products based on these kinds of perimeters. In summary, firstly the basic foundation of this pyramid is about the safety of these products, the second is the nutritional value and thirdly there must be the service to satisfy consumers for the long term. Some of the most important quality aspects are quality of content and physical-chemical condition, hygiene quality (bacteriological and cytological traits, absence of pathogens and other contaminants), sensorial quality, nutritional quality and technological quality (processing ability) (Karakok 2007).
low in cost, both product and process oriented, and not requiring much labour. ISO is very laborious and costly as well as far too non-specific to make it truly workable for a dairy farmer. In any case, a sound quality attitude of farmers and others involved is needed before one should even think about introducing HACCP or ISO (Noordhuizen and Metz 2005). The application of HACCP has been incorporated into Codex guidance texts (Codex Alimentarius Commission). The determination of a CCP in the HACCP system can be facilitated by the application of a decision tree, which indicates a logic reasoning approach. Application of a decision tree should be flexible, given whether the operation is for production, slaughter, processing, storage, distribution or other efficient and accurate record keeping is essential to the application of a HACCP system. HACCP procedures should be documented. Documentation and record keeping should be appropriate to the nature and size of the operation (CAC RCP 11969). Milk should not contain any contaminant at a level that jeopardizes the appropriate level of public health protection, when presented to the consumer. Contamination of milk from animal and environmental sources during primary production should be minimized. Water used in primary production operations should be suitable for its intended purpose and should not contribute to the introduction of hazards in milk (CAC/RCP 572004).
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The quality of yoghurt depends on the type of raw material used, on the manufacturing procedure employed and on the proper functioning of the process equipment and process line. The physical and chemical properties of yoghurt change during microbial fermentation with Lactobacillus bulgaricus and Streptococcus thermophilus. Other processing steps during yoghurt manufacture, including homogenization, heat treatment, mechanical handling, cooling, etc. have physico-chemical and biochemical effects. Processing is qualitycontrolled: milk is aseptically inoculated with starter culture; temperature is precisely monitored; and the yoghurt cooled quickly when the desired acidity is reached (Sandrou and Arvanitoyannis 2000). Cheese making is the process of removing water, lactose and some minerals from milk to produce a concentrate of milk fat and protein. The essential ingredients for cheese are milk, rennet, starter cultures and salt. The semi-firm gel is formed by adding rennet that causes the milk proteins to aggregate at a certain pH; then, it is cut into small curds. Then, the whey (mostly water and lactose) begins to separate from the curds. Acid production by bacterial cultures is essential to aid in the expulsion of whey from the curd and largely determines the final cheese moisture, flavor and texture (Zhao 2003). Ice cream and other whipped frozen dairy desserts are foams made up of air cells surrounded by a partially frozen emulsion. Ice cream consists mainly of water, fat, and milk solidsnon-fat, in combination with sugars, emulsifiers-stabilizers, colorings, flavorings, and fruits or nuts. The purpose of auxiliary materials is to increase the satisfaction value of the products. Ice cream is a product obtained from controlled raw materials, processed through pasteurization, homogenization, maturation, cooling, freezing, through keeping the air in composition, with or without glazer, and sell in different casseroles or waffle. The analysis and evaluation concluded that pasteurization is the most appropriate stage high potential risk in getting ice cream. Rapid cooling at temperatures below 5C should follow pasteurization, otherwise the viscosity of mix can increase considerably and melting of the ice cream will not be uniform. To ensure adequate freezing of the mix, the suitable type of freezer should be selected and its proper and safe operation should be maintained. Ice cream should be transferred to the hardening room immediately after freezing where the appropriate combination of temperature/time should be applied. Rapid hardening of ice cream is important for two reasons; first to prevent melting and formation of large ice crystals during refreezing and second to improve the sensory properties (e.g., texture and palatability) of the ice cream (Sandrou and Arvanitoyannis 2000; Panfiloiu et al. 2010). Butter is a dairy product that is produced physically from milk, cream, or yogurt and it should not include fat/oil other than milk fat. Components of the product are determined by food legislation of related countries. But in general the product should include 80-84% milk fat, 15.3-15.9% water, approximately 1% nonfat dry matter and 0.03-1.8% salt. Butter should be produced using cream or yoghurt and its fat content should be at least 82% according to related Standard (Altun et al. 2011). To produce a high quality butter, it is essential to ensure correct treatment of cream after separation since the temperature at which this process is carried out enhances microbiological growth. Heating of cream by direct steam injection in combination with vacuum deodorization should be avoided because it causes high fat losses in buttermilk and deterioration of butter flavor. Mixing of different quality creams should also be avoided since it can barely wipe out the defects of the used raw materials (Sandrou and Arvanitoyannis 2000).
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Chemical contaminants in milk comprise chemical hazards that may introduce during milk production, dairy processing or packaging. Veterinary drugs, heavy metals, radionuclides, mycotoxins and pesticides are chemical contaminants that can enter to animal feed and they have some residues in milk. The most contentious residues that ocur in milk are antimicrobial drugs. Total quality management and HACCP approach has an important role for preventing and controlling of chemical contaminants in milk and dairy products, especially antibiotics in raw milk shipped from the farm (Janed Khaniki 2007). Various hazards shown in Table 1 (Chandan et.al. 2008). Table 1 .Various Biological, Chemical and Physical Hazards Associated with Dairy Products Condensed Fluid Milk Cheese Ice Cream Dried Milk Product Biological Chemical Biological Biological Biological Biological Salmonella Antibiotics Salmonella Salmonella Salmonella Salmonella L.Monocytogenes Pesticides L.Monocytogenes Mold Spores L.Monocytogenes L.Monocytogenes S.aureus Sulfonamides S.aureus L.monocytogenes S.aureus S.aureus S.enteretoxin S.enteretoxin E.coli S.enteretoxin S.enteretoxin C.perfringens E.coli S.aureus E.coli C.perfringens Campylobacter E.coli C.botulinum Yersinia Shigella Yersinia C.perfringens Campylobacter Brucella Campylobacter B.cereus C.botulinum B.cereus Shigella Brucella Shigella Brucella Physical Chemical Chemical Chemical Chemical Insects Nitrates, nitrites Non-Food Sulfonamides Antibiotics Soil Aflatoxin Chemical Vapors Antibiotics Pesticides Glass Pesticides Fragments Wood Slivers Metal fragments
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from infections, should conform to hygienic rules, and should not have access to stables in order to avoid contamination of milk with pathogens of human origin (Sandrou and Arvanitoyannis 2000). Milk tankers should be cleaned and disinfected after discharging. Discharging areas should have adequate drainage and should be easily rinsed to avoid accumulation of water and raw milk residues. Milk should be conveyed from the tanker into the dairy building in closed hose or pipe systems. On receipt, raw milk should be subjected to the following controls by analytical laboratories performed according to Good Laboratory Practice for quality assessment : measurement of pH value and of titratable acidity; tests for sediment and antibiotic residues; measurement of temperature, which should not exceed 10C; determination of its microbiological quality through validated rapid methods; determination of its composition; tests to ensure that milk has not been adulterated; somatic cell count (Sandrou and Arvanitoyannis 2000). The management of the quality by risk analysis or identification of potential hazards linked to a product or a process (Hazard Analysis and Critical Control Points or HACCP-type approach), must be applied along the whole supply chain, from the cow to the consumer. For each identified potential risk, one identifies feasible corrective actions and control plans. A quantitative risk assessment determines the probability that the exposure to a particular risk can cause a disease for a given individual. It is necessary to take in account the predisposition or the sensibility of certain consumers to pathogenic agents. The risk factors linked to a consumer are age, immune system defenses, sex and stress levels. The measure of quantitative risks allows for the calculation of an acceptable risk level and for the establishment of quality norms or criteria adapted to the different situations (Faye and Loiseau 2000). Possible hazards, control and orientation of milk and milk products were shown in Table 2,3,4,5,6,7,8 (Papademas and Bintsis 2010 and Varnam and Sutherland 2001). Table 2. Possible hazards, control and orientation of raw milk Hazards Control Breast and nipples infected with bacteria found in urine and feces Breast and nipples infected with bacteria found in urine and feces Breast infected with at cleaning and drying Milking place Preliminary milking The infection of the hands of the person doing the milking Equipments not designed well especially, growth of bacteria as a result of not enough cleaning at rubber parts Growth of bacteria due to bad physical conditions, insufficient cooling and insufficient cleaning Brush of appropriate places and after that control of shaking with clear water Cleaning with brush using allowed chemical materials when the tanks are empty and shaking with clean water Beds must be designed by limiting the dirtiness at breast and nipples Beds are dry and clean Cleaning the floor, wall and equipments after every milking Cleaning the breasts with allowed chemical materials and drying them Not contact with other milks and cows milk thrown out
Orientation
If required, the beds are changed and good management provides nutrient field keep clean on regular basis Ensuring that the use of allowed cleaning materials after milking Ensuring that the use of allowed cleaning materials after milking Provision is made to control the waters on a regular basis Before milking, washing the hands or providing putting on rubber gloves Providing cleanliness using allowed chemical materials after every milking
Milking equipments
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Table 3. Possible hazards, control and orientation of pasteurized milk Process Level Hazards Control Orientation Raw milk infected with Bacteriological Not providing processed milk in Raw milk taking pathogen quality of milk contact with raw milk microorganisms Storage temperature Providing cleaning of store with at 5 0C or lower Growth of some bacteria Storage in cold appropriate hygienic rules after in milk Storage milk more milk taken from store than specific time Pasteurization (HTST- high temperature short time) Cooling after pasteurization Filling th bottles or cartons Storage in cold and transport The provision for keeping regular records of pasteurization Providing the prevention of Controlling working infection using appropriate of equipments to be cleaning and disinfection desired methods Cooling fastly at -10 0 C or belove this Being the bottles washed well and cartons cleaned Protection at refrigerator temperature Providing cleaning of tanks Providing protection of bottles and cartons in hygienic conditions Providing protection in cold Doing phosphatase test
Infection after pasteurization and growth of bacteria Infection of bottles and cartons Growth of bacteria in infected ones
Process Level
Table 4. Possible hazards, control and orientation of UHT milk Hazards Control Orientation To be found and growth of microorganisms caused food borne diseases Hygiene of milk collecting at farms Design and hygiene of collecting tanks and storage vessels Temperature and time of milk waited in containers Usage of seperator and design it hygienic Design of UHT sterilizator Place sterilizator correctly Recording of milk temperature Microbiological tests Providing hygienic of collecting tanks and storage containers Providing hygienic equipments and appropriate processing conditions Providing suitability of temperature and flowing velocity Control of flowing valve
Raw material
Microbial growth
Specification of milk flow rate Providing control of dirtiness including pressure and temperature at on plaques and visual cleaning sterilization of equipments and corrosion Hygienic design of refrigerator and homogenizator Correct collecting and planned preservation Cleaning of package surfaces (including closing chin) Convenience with specification of machine and packaging materials Sterility and cleaning of homogenizator
Not be sterile inside of aseptic Design of aseptic packaging machine packaging machine or The process of packaging according packaging to the manufacturer requests material or filling 528
Activity of packaging machine during usage Fitting trained stuff Specification of packaging material Packages seen treatment manually after filling and closing Packaging with cartons designed to protect from damage during transportation
Recording of the performance of the machine Closing in good way Conditions found at packages after packager
Control humidity to prevent becoming dense on packages Correctly stacking packages during storage and distribution Giving information to distribitors, shops and consumers about how the packages will be used
Table 5. Possible hazards, control and orientation of yoghurt production Process Level Hazards Control Orientation Concentrated nonfat Providing of recording milk seen thermal Finding of pathogenic Application of thermal process temperature process for 20 minutes microorganisms thermal processing and time at 85 0C Addition of additive To be infected with Food additive Providing usage of additive materials (stabilizators, food additive materials compliance material with suitable quality sugar syrup) materials with specification Thermal process (12 The killing of minutes at 90 0C) Providing of recording contaminated thermal process temperature bacteria for growth Cooling inoculation at and time of culture 400C Incubation Control of pH Cooling Packaging Cooling Storage at refrigerator and distribution Microbial infection Damaging of packages physically Providing to prevent growth of microorganisms infected with low pH Providing of keeping packaging materials at hygienic conditions Educating people with process techniques
Table 6. Possible hazards, control and orientation of cheese production Process Level Hazards Control Orientation Raw milk can be infected Control of Providing milk obtained Milk standardization with pathogen bacteriological quality of with good quality microorganisms milk The control of Providing records of Failure of pasteurization pasteurization Pasteurization (HTST) pasteurization time and causes live pathogens effectiveness with temperature phosphatase test Slow acid formation can Providing starter obtained Addition of starter cause growth of other Control of acid to minimize infection cultures bacteria including formation from trusted sources pathogens 529
Addition of enzyme (rennet) Discontinuation of clot Boiling (Temperature rises about 40 0C) Seperation of whey water Compression and salting Packaging Maturing Table 7. Possible hazards, control and orientation of ice-cream production Process Level Hazards Control Orientation Mixing of additivites Providing usage of including skim milk To be infected with Compliance of additives appropriate quality powder, oil of milk and additives with specifications additives sugar Failure of Ensuring compliance The control of Pasteurization pasteurization causes with the official pasteurization effectiveness live pathogens standards Providing implementation of Infection after Adequacy of implemented Homogenizing adequate clean-up pasteurization cleaning program programs Cooling and storage of Providing appropriate mixture in the refrigerator Microbial infection Temperature control temperature Freezing of icecream Packaging Microbial infection Hardening and storage Cleaning of package equipments Packaging materials should be stored in good hygienic conditions Microbial infection Measuring pH for fermentation control Using appropriate cleaning programs
Process Level Raw milk Seperation and pasteurization of cream Cooling below 5 0C and maturing Brine addition for setting saltwater ratio
Table 8. Possible hazards, control and orientation of butter production Hazards Control Orientation Raw milk can infect with Providing seperation of raw Bacteriological quality of pathogenic milk with heat processed milk at cooling storage microorganisms product Control of pasteurization effectivity with phosphatase test
6. Conclusions
The study designed an HACCP plan model, food safety management systems and the applicability of this systems for raw milk, pasteurized milk, UHT milk, yoghurt, cheese, butter and ice-cream to improve the safety and quality of products. This study proves that with only some adaptations and modifications, the HACCP systems can be developed and carried out in an individual way in dairy industry to get high quality products.
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The use of food safety and quality assurance in farms and plants is very important to reduce chemical and microbiological hazards in milk and dairy products. A regulatory law implementation in milk and dairy industries and long term planning is required to achieve milk safety. In addition, there are other items such as training of personel or latest good manufacturing practices and monitoring. Firstly, the milk and milk product (pasteurized milk, UHT milk, yoghurt, cheese, butter, ice-cream) processes were investigated. Then application of HACCP at dairy industry were performed to improve the safety and quality of its products. HACCP is a universal system that ensures the food safety for import and export of dairy products. As a result, description of the critical points in which hazards can intervene in the production processes of milk and milk products, evaluation and orientation applied to prevent and control the critical points were presented. From the literature review, it was observed that HACCP is an improved system compared to the traditional sampling and testing of quality control. Not only because it is a prevention instead of a reaction which reduces the risk of processing and selling unsafe products, but also because it is a cost-effective program which is fairly useful in milk and milk products production. Operational pre-requisite programs and risk analysis need to be established for the effective applicability of HACCP that determine physical, chemical and microbiological hazards in dairy industry. Altun I., Ands S., Tuntrk Y., een A., Fndk O., Some chemical characteristics of butters obtained from Van market, Kafkas Univ Vet Fak Derg, vol. 17, no. 4, pp. 645-648, 2011. CAC RCP 1- 1969, Recommended International Code of Practice-General Principles of Food Hygiene; incorporetes Hazard Analysis and Critical Control Point (HACCP) system and guidelines for its application, Rev.4-2003. CAC/RCP 57-2004, Code of Hygienic Practice for Milk and Milk Products Cannas J. and Noordhuizen J., Consumer safety and HACCP-like quality risk management programs on dairy farms: the role of veterinarians, ,The Open Veterinary ScienceJournal, vol 2, pp. 37-49, 2008. Cerf O., Donnat E., the farm HACCP working group, Application of hazard analysis - Critical control point (HACCP) principles to primary production: What is feasible and desirable?, Food Control ,vol 22, pp. 1839 - 1843 , 2011. Chandan R.C., Kilara A., Shah N.P., Dairy processing & quality assurance, Wiley-Blackwell, 2008. Deeth H. C., Datta N. Ultra-High temperature treatment (UHT): Heating systems, Elsevier, pp. 696-707, 2011. Faye B., Loiseau G., Sources of contamination in dairy supply chains and approaches to quality control, Proceedings of the International Workshop, Montpellier, France, 11-13 December 2000. Janed Khaniki Gh. R., Chemical contaminants in milk and public health concerns: a review, International Journal of Dairy Science, vol. 2, no.2, pp. 104- 115, 2007. Karakk G. S., Quality concept for dairy profitability,Hayvansal retim, vol. 48, no. 2, pp. 60-64, 2007. Meunier-Goddik L., Sandra S., Liquid milk products: pasteurized milk, Encyclopedia of Dairy Sciences (Second Edition), pp. 274-280, 2011. Noordhuizen J.P.T.M., Metz J.H.M., Quality control on dairy farms with emphasis on public health, food safety, animal health and welfare, Livestock Production Science, vol. 94, pp. 51-59, 2005. Panfiloiu M., Firczak M., Perju D.M., Simion G., Quality control of ice-cream products using the HACCP method, Banats Journal of Biotechnology ,vol. 2, pp. 61-65, 2010. Papademas P., Bintsis T., Food safety management systems (FSMS) in the dairy industry: a review, International Journal of Dairy Technology vol. 63, no. 4, pp. 489-503, 2010. Rosenberg M. Liquid milk products: UHT sterilized milks, Elsevier, pp. 288-296, 2002. Sandrou D. K., Arvanitoyannis I. S. Implementaton of hazard analyss critical control point (Haccp) to the dairy industry: current status and perspectives, Food Rev. Int., vol. 16, no. 1,pp. 77111, 2000. Varnam Alan H. and Sutherland Jane P., Milk and milk products : technology, chemistry and microbiology, Apsen Publication, 2001. Vilar M.J., Rodrguez-Otero J.L., Sanjuan M.L., Dieguez F.J., Varela M. and Yus E., Implementation of HACCP to control the influence of milking equipment and cooling tank on the milk quality, Trends in Food Science & Technology pp. 1- 9, 2011. Zhao M., The design of Haccp plan for a small-scale cheese plant, Submitted in Partial Fulfillment of the Requirements for the Master of Science Degree In Food and Nutritional Sciences, 2003.
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