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8/2/2019 Creamery Juice HACCP Plan
1/27
Penn State Berkey Creamery Juice HACCP 2010
Page1of27
Berkey Creamery
JuiceHACCPPlan
EditedMay,2010.
By:
BenjaminThomas
8/2/2019 Creamery Juice HACCP Plan
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Penn State Berkey Creamery Juice HACCP 2010
Page2of27
TableofContents:
HACCPTeamandProductStatementwithProcessFlowDiagram pg.3
HACCPVerificationSheet pg.4
HazardAnalysisSummaryTable pg.5
HACCPPlanSummaryTable pg.6
SOP002.002(OrangeJuiceProduction) pg.7
8SSOPs pg.9
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Penn State Berkey Creamery Juice HACCP 2010
Page3of27
HACCPTeamforthePennStateBerkeyCreamery:
Dr.LukeLaBorde Mr.ThomasPalchak Mr.JamesBrown
Ms.BonnieFord Mr.WilliamKurtz Ms.SusanWatson
Mr.JerryWinn
BERKEY CREAMERY PRODUCTION AND DISTRIBUTION FLOW DIAGRAM
Product: 100%PureFloridaOrangeJuicefromConcentrate
Ingredients: Water,orangejuiceconcentrate
Processing: Allingredientsarepasteurized
LabelingandUseInstruction: Codedwithsellbydate,andkeeprefrigerated
ConfirmatoryTest: Noproteinpresentinproduct
Packaging:
1gal,1/2gal,
qt,
and
pint
HDPE
plastic
bottles
with
tamperevidentseals.
TransportationandDistribution: Storedanddistributedunder40F
IntendedConsumers: UniversitydininghallsandCreamerystore
ShelfLife 45daysfromcodedating
Orange
JuiceConcentrate
Received andstored under
(-20F)
Drums thawed and
stored under 40F
Mixing(balance tank of
HTST)
University WaterSupply
Water Softener
Pasteurization
(CPP#1)
PasteurizedStorage at or
below 40F
Packaging
Verification of Brix
(11.8-12.2%)
1 gal bottles
gal
bottles
Quart
bottles
Pint bottles
Storage and
Distribution
(under 40F)
ConfirmatoryTest for
Protein
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Penn State Berkey Creamery Juice HACCP 2010
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BERKEY CREAMERY HACCP SYSTEM VERIFICATION SHEET
EvaluationofProductandProcess YES No If Yes,describe FoodSafety
Implications
Aremodificationsof
theHACCPplanof
HazardAnalysis
required?
Productdescriptionchange?
Formulationchange?
Ingredientchange?
Packagingchange?
Newconsumptionorstoragemethods?
Newsuppliers?
ProcessChange?
Addedorchangedequipment?
Finishedproductdescriptionchange?
EvaluationofProductSafetyHistoryExcessiveCCPdeviations?
Anyproductrecall?
Anyneworemerginghazards?
Anyfoodsafetyconsumercomplaints?
EvaluationofCCPs,Criticallimits,Monitoring,Correctiveactions,CCPVerification,RecordkeepingDotheCCPscontrolthehazard?
AretheCCPcriticallimitsadequate?
Domonitoringmethodsandtheir
frequencyadequatelyidentify
deviations?
Arerecordkeepingprocedures
adequate?
Doverificationactivitiesincludethe
calibrationofprocessmonitoring
instruments?
Doesverificationincludereviewof
consumercomplaints?
Doesverificationincludethereviewof
records?
Aretheprerequisiteprogramsand/or
SSOPsidentifiedinthehazardanalysis
asreducingthelikelihoodofhazards
stilleffective?
Verificationconductedby:__________________________________________
SignatureofLaboratoryDirector:_____________________________________
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Penn State Berkey Creamery Juice HACCP 2010
BerkeyCreameryHazardAnalysisSummaryTable
Product:100%
Pure
Florida
Orange
Juice
from
Concentrate
Process,Step,IngredientorInput IdentifythePotentialHazard
(B)iological
(C)hemical
(P)hysical
Isthehazardsevereand
ofsufficientlikelihoodto
warrantitscontrol?
Isacontrolmeasureavailableatthishazard
correctlyapplied,monitored,anddocumen
inaPrerequisiteProgram(PP)orother
procedure?
Ifnot,couldandexistingPPbemodifiedor
newPPestablishedtocontrolthehazard.
Ifso,identifythePPanditslocation
Ifyes,stopanddocument
Ifno,proceedtonextquestion
OrangeJuiceConcentrateReceiving B
C
P
Yes
Yes
Yes
No
Yes:CertificateofAnalysis;Productseals
Yes:CertificateofAnalysis;ProductSeals
ConcentrateStorage B
CP
No
NoNo
Ingredients:Water B
C
P
Yes
Yes
Yes
No
Yes:Mustbepotable;commerciallabcertifica
No
Pasteurization B
C
P
Yes
No
No
No
Packaging B
C
P
Yes
No
No
Yes:LetterofGuarantee
Yes:LetterofGuarantee
Yes:LetterofGuarantee
ProductStorage B
C
P
Yes
No
No
Yes:SSOPsandGMPtraining
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Penn State Berkey Creamery Juice HACCP 2010BerkeyCreameryHazardAnalysisSummaryTable
Product:100%PureFloridaOrangeJuicefromConcentrate
CriticalControl
Point
Hazards CriticalLimits Monitoring CorrectiveA
What How Frequency Who
CPP#1
Pasteurization
(HTSTwithouta
magneticflow
metersystem)
Biological
Vegetative
Pathogens(non
sporeformers)
Temperatureas
measuredatthe
exitoftheholding
tubemustexceed
161F
HoldingTimemust
begreaterthan15
seconds
Pressuredifferential
between
pasteurizedand
rawproductmust
begreaterthan
1p.s.i
Temperature
Time
Pressure
Safety
thermallimit
recorderand
chartrecorder
Timingpump
Pressuredifferential
controller
Continuous Pasteurizer
operators
Automaticdiv
ofproductflo
Isolationofaf
product
Evaluateand
determinethe
dispositionof
product
Documentall
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SOP:002.002 EffectiveDate: 11/29/06
Supersedes SOP:002.001 EffectiveDate: 08/25/04
STANDARDOPERATINGPROCEDUREOrangeJuiceProduction
INTRODUCTION
Orangejuiceispreparedfromaconcentrate,pasteurized,andthenpackagedforwholesaleandretail
distribution.
MATERIALS
1. Supplies
a. Sanitizer
b. Swabsthatdetectmilkprotein
c. Orangejuiceconcentrate
d. Brixrefractometer
e. Chartpaper
f. Recordofmanufactureform
2. Hazards
a. Burnsfromhotwaterandhotmetal.
b. Corrosivedamagetoeyesandskinfromsanitizer. Weargogglesandgloveswhenusingthe
concentrate.
Avoidbreathing
the
vapors.
PROCEDURE
1. Preproductionsanitation
a. Discardthesanitizingsolutionthatwasheldinthefillerbowls,allowingittoflowthroughthe
fillertubesandontothefloor.
b. Prepareatleast300gallonsofsanitizingsolutioninamixingtank. Testtheconcentrationand
recordtheresultonthesanitationtestrecord.
c. PumpthesanitizingsolutionthroughthelinesleadingtotheHTST,throughtheHTST,andthen
tothetankthatwillbeusedfororangejuiceproduction. Finally,pumpthesanitizingsolution
fromthe
orange
juice
production
tank
through
the
lines
to
the
fillers,
allowing
it
to
overflow
the
bowlsandtoflowthroughallofthefillertubesandthenontothefloor.
d. StarttheHTSTandpasteurizesomewater. Runthiswaterthroughthelinesleadingtothetank
thatwillbeusedfororangejuiceproduction,thenthroughthelinestothefillers. Allowthe
pasteurizedwatertooverflowthebowlsandtoflowthroughallofthefillertubesandthenonto
thefloor.
e. Swabfoodcontactsurfaces. Ifresultsindicatethepresenceofmilkproteinresiduesrepeatthe
sanitationprocedure.
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2. Production
1. Allowthefrozenorangejuiceconcentratetothawat
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SSOP: 001.002 EffectiveDate: 11/22/06
Supersedes SSOP: 001.001 EffectiveDate: 10/22/04
SANITATIONSTANDARDOPERATINGPROCEDUREWater,Steam,andIceSafety
INTRODUCTION
Wateriscriticalforfoodproductionandplantsanitation. Potablewater,coolingwater,steamandice
mustbesafeanditmustbeavailableinsufficientquantities,atsuitablepressuresandtemperatures,tomeet
operationalrequirements.
TheBerkeyCreameryusestreatedwaterfromwellfieldsownedandmaintainedbyThePennsylvania
State
University.
These
wells
provide
water
for
the
University
Park
Campus
of
Penn
State
and
are
the
state
approvedsourceofallwaterneeds,includingthecleaningandrinsingofequipment.
FACILITIES
1. Potablewatersupply:
a. Thepotablewatersupply,includingthesoftwatersystem,ismaintainedbythePennsylvania
StateUniversitiesOfficeofPhysicalPlant. Allwaterenteringthebuilding,includingthewater
thatisusedasaningredientorthatgoestotherefrigerationsystem,passesthrougha
chlorinationprocess.
b. BacteriologicaltestingofthepotablewaterisconductedmonthlybyPennStateand
semiannuallybyanapprovedcommerciallaboratory.
c. Waterpipes,hoses,andotherconnectionsthatcouldpossiblyresultincontaminationofthe
potablewatersupplymustbeequippedwithproperlydesignedphysicalbreaks,antisiphonor
antibackflowdevices.
d. Crossconnectionsbetweenpotableandnonpotablewatersupplysystemsmustnotexist.
2. Coolingwatersupply:
a. Thecoolingwatersupplyismaintainedandtestedmonthlybyacommercialwatertreatment
company.
b. Watertreatmentchemicalsmaybeaddedaccordingtothemanufacturers directionswhen
needed.
c. Bacteriologicaltestingofthecoolingwaterisconductedsemiannuallybyanapproved
commerciallaboratory.
3. Steamsupply:
a. ThesteamsupplyismaintainedbythePennsylvaniaStateUniversityOfficeofPhysicalPlant.
b. Unfilteredsteam
does
not
come
into
direct
contact
with
food
or
food
contact
surfaces.
c. Filteredsteamoriginatesfrompotablewater.
d. Culinarysteamiscarbonfiltered.Thefilteristobechangedeverysixmonths,andverification
recordskept.
4. Icesupply:
a. IcemakingmachinesaremaintainedbythePennsylvaniaStateUniversityOfficeofPhysicalPlant.
b. Alliceismadefrompotablewater.
c. Iceishandledandstoredinamannerthatprotectsitfromcontamination.
5. Reclaimedwatersupply:
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a. TheCreamerydoesnotusereclaimedwater.
6. Distilledwatersupply:
a. ThedistilledwatersupplyismaintainedbythePennsylvaniaStateUniversityOfficeofPhysical
Plant.
RECORDKEEPING
1. TheUniversitymaintainsdocumentationonthewatertestsconductedforchemical,microbiological,
turbidityandradiologicalparameters.
2. MicrobiologicaltestresultsofthewatersupplythatareconductedbyPennStatearemaintainedinthe
OfficeofPhysicalPlant.
3. AllotherresultsfromtheanalysisofthepotableandcoolingwatersuppliesaremaintainedattheBerkey
Creameryforatleasttwoyears.
ThefollowingindividualisresponsibleforimplementationofthisSSOPandhastheoverallauthorityonsite:
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Penn State Berkey Creamery Juice HACCP 2010
Page11of27
Name:____________________________Title:__________________________Date:_______________
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Penn State Berkey Creamery Juice HACCP 2010
Page12of27
SSOP: 002.001 EffectiveDate: 01/12/07
SANITATIONSTANDARDOPERATINGPROCEDUREProcessingEquipmentCleaningand
Sanitation
INTRODUCTION
Cleanandsanitizedprocessingequipmentandutensilsareessentialtothemanufactureofsafefood
products. Processingequipmentiscleanedaftereachdaysrunandsanitizedimmediatelypriortothenext
use. Mostequipmentinadairyplantiscleanedinplace(CIP)usingacomputercontrolledmultistepsystem.
ItemsthatcannotbecleanedwiththeCIPsystemmustbecleanedandsanitizedaftereachusebyhandorina
COP(cleanedoutofplace)tub.
MATERIALS
1. Supplies
a. Cleaningandsanitizingagents
b. Cleaningequipmentsuchasgloves,brushes,buckets,andfoamsprayers
c. COPtub
d. Sanitationtestrecords
2. Hazards
a. Burnsfromhotwaterandhotmetalparts
b. Chemicalburnstotheskinandeyesfromexposuretocleanersandsanitizers. Wearglovesand
goggleswhenusingtheconcentratedchemicals. Avoidbreathingthevapors.
HANDCLEANINGPROCEDURE
1. UtensilsanditemsthatcannotbeadequatelycleanedwiththeCIPsystemmustbehandwashed.
2. Theseitemsaredismantledandprerinsedwithwatertoremovetheheavysoil,thenhandscrubbed
usingachlorinatedalkalinedetergent,andrinsedagainwithwater. Wirescreensmustbeautoclaved
followinghandwashing.
3. ThecleaneditemsarereassembledandsanitizedpriortouseusingtheCIPsanitizingcircuitifpossibleor
dippedinasanitizingsolution.
CLEANEDOUTOFPLACEPROCEDURE
1. Dismantleequipmenttobecleanedandrinsewithwater.
2. PlacethepartsinaCOPtubandfillthetubwithapproximately150to200gallonsofwater.
3. Turnthecirculationpumponandheatthewaterto170F.
4. Slowlyaddthenecessaryamountofchlorinatedalkalinecleaner.
5. Collectasampleofthecleaningsolutionandtestthealkalinityandchlorineconcentrations.
6. Circulatehotwaterandcleanerforatleast30minutes.
7. AllowtheCOPtubtoemptyintoafloordrain.
8. Rinsetheequipmentwithanapprovedsanitizer.
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9. Visuallyinspecteachpieceofequipmentforpossibledamageandthepresenceofresidualcleaner.
10. Reassembletheequipmentandreturnittoitsstoragearea.
OPERATIONOFTHERAWCIPCIRCUIT
1. TherawCIPcircuitisusedtocleanthemilkdeliverytruck,therawmilksilo,therawmilkreceivinglines
andpumpaswellastherawlinesleadingtotheprocessingplant. Additionally,thetwomixingtanksand
theBreddoLiqwifierarecleanedandsanitizedusingtherawCIPcircuit.
2. Ifneeded,theequipmentisprerinsedwithwatertoremovemostoftheresidualproduct.
3. ThenecessarylineconnectionsaremadeandtherawCIPprogramisactivated.
a. Thefirststepisawaterrinse
b. Thenwaterisheatedandachlorinatedalkalinedetergentisadded. Thissolutioniscirculated
throughoutthecircuitwhilevalvesandagitatorsareperiodicallypulsedtoaidinsoilremoval.
c. Thewashcycleisfollowedbyawaterrinsewhichcoolsdownthecircuit.
d. Finallyanacidsanitizerisadded,circulatedthroughoutthecircuit,andallowedtodraintothe
floor.
e. Thelineconnectionsarereturnedtotheiroriginalconfiguration.
4. Priorto
the
equipments
next
use
aCIP
sanitation
step
is
performed
using
an
acid
sanitizer.
OPERATIONOFTHEPASTEURIZEDCIPCRICUIT
1. ThepasteurizedCIPcircuitisusedtocleantheallofthepasteurizedstoragetanks,fillerlines,andthe
bottleandbagfillingequipment.
2. Ifneeded,theequipmentisprerinsedwithwatertoremovemostoftheresidualproduct.
3. ThenecessarylineconnectionsaremadeandthepasteurizedCIPprogramisactivated.
a. Thefirststepisawaterrinse
b. Thenwaterisheatedandachlorinatedalkalinedetergentisadded. Thissolutioniscirculated
throughoutthecircuitwhilevalvesandagitatorsareperiodicallypulsedtoaidinsoilremoval.
c. Thewash
cycle
is
followed
by
awater
rinse
which
cools
down
the
circuit.
d. Finallyanacidsanitizerisadded,circulatedthroughoutthecircuit,andallowedtodraintothe
floor.
e. Thelineconnectionsarereturnedtotheiroriginalconfiguration.
4. PriortotheequipmentsnextuseaCIPsanitationstepisperformedusinganacidsanitizer.
OPERATIONOFTHEHTSTCIPCIRCUIT
1. TheHTSTCIPcircuitisusedtocleanthebowl,homogenizer,separator,andpasteurizer,allofthelines
connectingthesepiecestoequipment,aswellasthelinesandvalvesleadingtothepasteurizedstorage
tanks.
2. Ifneeded,theequipmentisprerinsedwithwaterandthebowlisallowedtooverflowwithwaterinorder
toremovemostoftheresidualproduct.
3. ThenecessarylineconnectionsaremadeandtheHTSTCIPprogramisactivatedfollowingtherequired
initialtenminutedelay.
a. Thefirststepisacausticrinseusinganalkalinecleaner. Thissolutioniscirculatedthroughout
thecircuitwhilevalvesareperiodicallypulsedtoaidinsoilremoval. Itisalsoallowedto
overflowthebowl.
b. Thecausticrinsecycleisfollowedbyawaterrinse.
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Page14of27
c. Thewateristhenheatedandanaciddetergentisadded. Thissolutioniscirculatedthroughout
thecircuitwhilevalvesareperiodicallypulsedtoaidinsoilremoval. Duringthistimethebowl
maybehandwashedifneeded.
d. Analkalinecleaneristhenaddedtotheaciddetergentthatisbeingcirculated(causticoverride).
Duringthistimetheheatismaintainedandthevalvescontinuetopulseperiodically.
e. Thewashcycleisfollowedbyawaterrinsewhichoverflowsthebowlandcoolsdownthecircuit.
f. Finallyanacidsanitizerisaddedandcirculatedthroughoutthecircuit. Thissanitizerremainsinthesystemuntiltheequipmentisusedagain.
g. Thelineconnectionsarereturnedtotheiroriginalconfiguration.
4. PriortotheequipmentsnextuseaCIPsanitationstepusinganacidsanitizerisperformed.
a. Theresidualacidsanitizer(fromstep3fabove)isrinsedoutwithwater.
b. Afreshsolutionofacidsanitizerispreparedinoneofthemixingtanks.
c. TheHTSTisstartedupusingitsproductsetting(notCIP)andhighspeed. Thiswillpumptheacid
sanitizerfromthemixingtankthroughalloftheequipmentthatisscheduledtobeusedthatday.
CLEANINGOFBURNEDONRESIDUE
1. Rinseout
residual
product.
2. Fillthetankwithwaterandaddapowderedchlorinateddetergent.
3. Heatthesolutiontoapproximately180Fandallowittosoakuntiltheresidueissoftenedandabletobe
removed.
4. MakethenecessaryCIPlineconnectionsandinitiatetheappropriateCIPprogram.
CLEANINGANDSANITATIONOFICECREAMPROCESSINGEQUIPMENT
1. TheicecreammixtanksarecleanedusingthepasteurizedCIPcircuitdescribedabove.
2. Theflavorvatsandicecreamfreezersarerinsedwithwaterfollowingeachuse. Thenasolutionofhot
waterandchlorinatedalkalinedetergentiscirculatedthroughthisequipmentandthelinesconnecting
them.
Followingthe
cleaning
step
the
equipment
is
rinsed
with
water.
3. Priortoeachdaysoperationsthepasteurizedlines,flavorvats,freezers,ingredientfeeder,halfgallonand
threegallonfillingequipment,aswellasallthelinesconnectingthisequipmentaresanitizedwitha
chlorinesanitizer. Residualsanitizerisflushedoutofthelinesbypumpingapproximatelythreegallonsof
icecreammixthroughthecircuitanddrainingitontothefloor. Ondayswhenthedixiecuporpintfilling
equipmentisuseditislikewisesanitizedpriortousewithachlorinesanitizerwhichisallowedtodrainto
thefloor.
4. Aftereachuse,thefillingequipmentisrinsedwithwatertoremovemostoftheresidualproduct. Thenit
ishandwashedwithachlorinatedalkalinedetergentandrinsedwithwateragain. Additionally,atthe
endofeachweekthefillingequipmentthathasbeenusediswashedusingaselffoamingchlorinated
alkalinedetergentandrinsedwithwater.
CLEANINGAND
SANITATION
OF
BEVERAGE
CONTAINER
FILLING
EQUIPMENT
1. ThefillinglinesandequipmentarecleanedandsanitizedusingthepasteurizedCIPcircuitdescribed
above.
2. Ondayswhendairyproductsarepackagedthefollowingadditionalcleaningandsanitizingstepsare
preformed.
a. Priortopackagingtheacidsanitizerwhichwasretainedinthefillerbowlsisdrainedthroughthe
fillertubesandontothefloor. Thenozzleheadsarealsosprayedwithanacidsanitizer.
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b. Atchangeovers(whenoneproductsisfinishedbeingpackagedandanotherbegins),theproduct
remaininginthebowlisexpelledthroughthefillertubes. Theareaisthenrinsedwithwaterand
sprayedwithanacidsanitizer.
c. Whenpackagingisfinished,theproductthatremainsinthebowlisexpelledthroughthefiller
tubesandtheareaisrinsedwithwater. ThebowlisflushedwithwaterandtheCIPconnection
tothefillerheadsismade. Allexteriorsurfacesarefirsthandwashedwithachlorinatedalkaline
detergent,thenwashedwithaselffoamingchlorinatedalkalinedetergentandrinsedwithwater.
3. Ondayswhennondairyproductsarepackagedthefollowingadditionalcleaningandsanitizingstepsare
preformed.
a. Priortopackaging,theacidsanitizerwhichwasretainedinthefillerbowlsisdrainedthroughthe
fillertubesandontothefloor. Anewsolutionofacidsanitizerispreparedinamixingtankand
pumpedthroughalloftheequipmentandtanksthatwillbeusedthatday. Itisalsoallowedto
overflowthebowlandflowthroughallofthefillertubes. Pasteurizedwateristhenpumped
throughalloftheequipment,bowlandfillertubes. Thenozzleheadsaresprayedwithanacid
sanitizer.
b. Atchangeovers,theproductremaininginthebowlisexpelledthroughthefillertubes. Thearea
isthenrinsedwithwaterandsprayedwithanacidsanitizer.
c. Whenpackagingisfinishedtheproductthatremainsinthebowlisexpelledthroughthefiller
tubesand
the
area
is
rinsed
with
water.
The
bowl
is
flushed
with
water
and
the
CIP
connection
tothefillerheadsismade. Allexteriorsurfacesarehandwashedwithachlorinatedalkaline
detergentandrinsedwithwater.
CLEANINGANDSANITATIONOFCHEESEPROCESSINGEQUIPMENT
1. Cheddarandricottavats
a. Thevatsaresanitizedpriortousewithanacidsanitizer.
b. Afterusetheresidualproductisrinsedoutwithwater.
c. Thevatsarethenfilledwithwaterandhandwashedusingbothapowderedchlorinated
detergentandachlorinatedalkalinedetergent.
d. Following
cleaning,
the
vats
are
thoroughly
rinsed
with
water.
2. Kettleandhomogenizer
a. Priortousethekettleisfilledwithwaterwhichisheatedto180C. Thiswateriscirculated
withinthekettle,pumpedthroughthelinestothehomogenizer,andthendrainedontothe
floor.
b. Followinguse,theresidualproductisrinsedoutofthekettlewithwater.
c. Thekettleisthenfilledwithwaterandapowderedchlorinateddetergentandheated. This
detergentsolutioniscirculatedwithinthekettle,pumpedthroughthelinestothehomogenizer,
andthendrainedontothefloor.
d. Additionally,thehomogenizerisdismantled,washedbyhandwithachlorinatedalkaline
detergentandrinsedwithwater.
3. Conebottomprocessorandpasteurizedstoragetank(PT6)
a. TheconebottomprocessorandPT6aresanitizedpriortousewithanacidsanitizer.
b. Followinguse,
the
residual
product
is
rinsed
out
with
water.
c. Thedoorgasket,filllines,andexteriorsurfacesarehandwashedwithachlorinatedalkaline
detergentandrinsedwithwater.
d. ThenthenecessarylineconnectionsaremadeandtheCIPprogramisactivated.
4. Yogurtfiller
a. Priortouseasolutionofchlorinatedalkalinecleanerispreparedandflushedfromthefiller
bowls,overthetrackandthendrainedontothefloor.
b. Followinguse,theresidualproductisrinsedoffwithwater.
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c. TheremovablepartsofthefillerarecleanedinaCOPtubwithapowderedchlorinateddetergent
andrinsedwithwater.
d. Allexteriorsurfacesarehandwashedwithachlorinatedalkalinedetergentandrinsedwith
water.
5. Cheddarprocessingequipment
a. Followingusethecheddarpressisrinsedwithwater,handwashedwithachlorinatedalkaline
detergent,andthenrinsedagain.
b. Thecheddarmillissanitizedpriortouse. Aftereachuseitisrinsedwithwater,handwashed
withachlorinatedalkalinedetergent,andthenrinsedagain.
c. Thevacuumpackagerissanitizedusingachlorinesoakedclothpriortouseandcleanedwithan
aerosolcleanerfollowinguse.
d. Thecheddarpansandlinersaredippedinasolutionofchlorinesanitizerpriortouse. Afteruse
thelinersarediscardedandthepansarerinsedwithwater. ThepansarethencleanedinaCOP
tubwithapowderedchlorinateddetergentandrinsedwithwater.
VALIDATION
1. Cleanedequipment
and
utensils
are
visually
inspected
to
determine
ifthey
are
free
of
residue
and
foreign
material.
2. PeriodicswabbingofcleanedequipmentwithATPbioluminescenceswabsisusedtomonitorfoodcontact
surfacesforthepresenceofresidualsoil.
3. Swabbingwithmilkproteindetectingswabspriortothemanufactureofnondairydrinksisusedto
monitorforpossiblecrosscontamination.
4. SamplesareautomaticallycollectedfromthevariouscycleswithineachCIPprogram. Thesearetitrated
todeterminetheirchemicalconcentration. Iftheconcentrationsarenotconsistentlywithinan
acceptablerangethechemicalinjectiontimewillbeadjusted.
RECORDKEEPING
1. Resultsfromthechemicaltitrationsofcleaningandsanitizingsolutionsarerecordedonthesanitation
testrecords. Thesetestsareperformedtodeterminetheconcentrationsofcleaningandsanitizing
solutionsusedinboththeCIPsystemandtheCOPtubs.
2. ResultsobtainedfromATPbioluminescenceswabsarerecordedonATPmonitoringforms.
3. Resultsobtainedfrommilkdetectionswabsarerecordedontherecordsofmanufacturefornondairy
drinks.
ThefollowingindividualisresponsibleforimplementationofthisSSOPandhastheoverallauthorityonsite:
Name:____________________________Title:__________________________Date:_______________
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SSOP: 003.003 EffectiveDate: 06/18/09
SupersededSSOP:003.002 EffectiveDate: 11/27/06
Supersedes SSOP: 003.001 EffectiveDate: 10/29/04
SANITATIONSTANDARDOPERATINGPROCEDURECrossContaminationPrevention
INTRODUCTION
Duringprocessingtherearenumerouswaysthataproductcanbecomecontaminatedwithamicrobiological
hazard. Thethreemostcommonmeansofcrosscontaminationarecontactwithuncleanequipment,mixing
pasteurizedwithrawproducts,andenvironmentalcontamination.
PROCEDURE
1. Periodicallymonitorequipmentsuchassilotanks,valves,agitatorshafts,shieldingandventingforcracks
andcrevices. Improperweldsandirregularsurfacesaredifficulttocleanandsanitizeproperlyandthus
canbecomeaharborageformicroorganisms.
2. Producthandling:
a. Minimizetheamountofafoodproductshandling,environmentalexposure,andtime/
temperatureabusefollowingpasteurization.
b. Discardanyproductthathasbeenmishandled,notprotectedfromcontamination,ornot
maintainedat45F(7.2C)orless.
c. Whenreclaimingproducts,repasteurizationisrequired,usinghighertemperaturesand/or
longerholdingtimes. Allequipmentinvolvedinthereclaimingprocessshouldbecleanedand
sanitizeddaily.
d. Isolatereturnedproductsandoutdatedproductsfromallotherplantoperations.
3. Cleaningsupplies:
a. Eliminatetheuseofabsorbentitemssuchasragsandspongesinprocessingareas,aswellas
porousmaterialssuchaswoodenhandledtoolsandbrushes. Useimperviousmaterialssuchas
metalorplasticinstead.
b. Brushesshouldbesegregated;rawandpasteurized,internalandexternalsurfaces.
c. Brushesshouldbemaintainedingoodcondition,sanitizedbetweenuses,andstoredproperly
whennotinuse.
4. Utilizeshieldingoverfoodandfoodcontactsurfacestominimizecontaminationwithcondensate,
aerosols,dust,andotherairbornehazards.
5. Monitorthecleanlinessofoverheadshielding,conveyors,conveyorbelts,chainrollersandsupports.
Maintain
a
cleaning
and
sanitizing
regimen
for
all
conveyors.
6. Airblowandagitationequipmentshouldbemonitoredforcleanliness. Thesearenotusuallycleaned
adequatelybyCIPmethodsandthereforeshouldbedismantled,cleanedmanually,andsanitizeddaily.
7. Donotbreakorslashcontainersovertopavat.
8. Exercisecarewhenhandlingpackingmaterials,especiallywhereopencontainersareconveyedthrough
nonprocessingareas.
9. Heating,ventilating,andairconditioningsystems:
a. Shouldmaintainpositivepressureinareaswherefoodproductsareexposed.
b. Minimizeairflowfrompotentiallycontaminatedareastoprocessingandpackagingareas.
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c. Outsideairshouldbefilteredandfreeofcondensate.
d. Airflowshouldbecontrolledsothatitdoesnotblowdirectlyontofood,foodcontactsurfaces,
aswellasfillingandpackagingareas.
e. Airfiltersmustbeeffectiveinpreventingthepassageofmicroorganisms. Theymustalsobekept
cleanandreplacedwhenneeded.
f. Allheating,ventilatingandairconditioningsystemsshouldbeperiodicallycleaned,includingair
systemsinrefrigeratedareas.
g. Condensatedrippansanddrainlinesshouldberegularlymonitoredtoensuretheyarenot
providinganenvironmentformicrobialgrowth.
10. Processairsystems:
a. Systemsthatincorporateairdirectlyintothefoodproductmustbeeasilycleanedanddesigned
tominimizecontamination.
b. Processairsystemsshouldcontainfiltersthatarecapableofremovingextraneousmatter.
c. Sanitarycheckvalvesthatpreventproductfrombackingupintotheairlinesshouldbeprovided
whennecessary.
11. UseofpushcartsintheFoodScienceBuilding:
a. ThereisariskofcrosscontaminationwhenpushcartsareremovedfromtheCreameryandused
totransportitemstothethirdandfourthfloorsintheFoodScienceBuildingandviceversa.
Thereforepush
carts
used
in
the
Creamery
processing
plant,
Food
Science
pilot
plants
and
sensorylaboratorywillhavebluetapeontheirhandles,andpushcartsforthethirdandfourth
floorswillhaveredtapeontheirhandles.
b. Bluelabeledcartsareusedtotransportfoodandfoodingredientsonthefirstandsecondfloors.
Inordertoimprovebarrierhygienemethodstheyshouldnotbetakentothefourthfloor.
c. Redlabeledpushcartsshouldnotcomeindirectcontactwithanyfoodoringredients. Items
sentorshippedtothethirdandfourthfloorsshouldbetransportedonredlabeledcartsora
dolly. Ifthesecartsareusedtotakesuppliesfromtheloadingdocktothethirdandfourth
floors,theyshouldnotleavetheimmediatevicinityofthefreightelevator. Whennotinusered
labeledcartsshouldbestoredonthethirdfourthfloors.
d. Containers,samples,ingredients,packagesandlaboratoryequipmentshouldnotbetransferred
fromonetypeofcarttoanother.
e. Ifyouhaveanysafetyconcernsorthinkthataccidentalcrosscontaminationhasoccurred,call
theCreameryofficeat8148657535immediately.
ThefollowingindividualisresponsibleforimplementationofthisSSOPandhastheoverallauthorityonsite:
Name:____________________________Title:__________________________Date:_______________
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Penn State Berkey Creamery Juice HACCP 2010
Page19of27
SSOP:004.002 EffectiveDate: 11/27/06
Supersedes SSOP: 004.001 EffectiveDate: 10/22/04
SANITATIONSTANDARDOPERATINGPROCEDUREMaintenanceofSanitaryFacilities
INTRODUCTION
Theproductionofsafefoodbeginswithpropersanitation. Inadditiontocleanfoodprocessing
equipment,thefacilitiesthatareassociatedwithfoodproductionareasmustbecleanandproperly
maintained.
MATERIALS
1. Cleaningequipmentandsupplies
2. Chemicalcleaningagentsarestoredinlockedroomsawayfromfoodhandlingareas.
FACILITIES
1. Washrooms,lunchrooms,andchangingrooms:
a. WashroomsaremaintainedbythePennsylvaniaStateUniversitiesOfficeofPhysicalPlant.
b. Washrooms,lunchroomsandchangingroomsshouldbeseparatefromandnotleaddirectlyinto
foodprocessingareas.
2. Handwashingandsanitizingfacilities:
a. Washroomsshouldhaveanadequatenumberofproperlymaintainedhandwashingfacilities
thatare
directly
connected
to
sanitary
drains.
b. Handwashingfacilitiesshouldhavehotandcoldpotablerunningwater,soap,sanitaryhand
dryingsuppliesordevices,andcleanwastereceptacles.
c. Processingareasshouldalsohaveanadequatenumberofconvenientlylocatedandproperly
installedhandwashingfacilities.
d. Itisrecommendedthathandwashingnoticesbepostedinstrategicpointsthroughoutthe
processingplanttoremindemployeesandvisitorstowashhandsafterusingthebathroom.
ThefollowingindividualisresponsibleforimplementationofthisSSOPandhastheoverallauthorityonsite:
Name:____________________________Title:__________________________Date:_______________
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Penn State Berkey Creamery Juice HACCP 2010
Page20of27
SSOP: 005.001 EffectiveDate:12/20/06
SANITATIONSTANDARDOPERATINGPROCEDUREAdulterationPrevention
INTRODUCTION
Food,foodpackagingmaterialsandfoodcontactsurfacesmustbeprotectedfromadulterationwith
physicalorchemicalhazards. Contaminantsmayincludewater,cleaners,sanitizers,lubricants,pesticides,
metal,rubberandplastic. Theinclusionofunintendedingredientsandundeclaredallergensisalsoconsidered
tobeproductadulteration.
GENERALADULTERATIONPREVENTIONPROCEDURES:
a. Reviewall
piping
to
ensure
that
products
are
not
being
contaminated.
a. Lookforlineswhereproducts,orcleaningandsanitizingsolutionscouldbecometrapped.
b. Examinedrainlinestomakesuretheyaredrainingfreelyexceptduringuse.
c. Monitorforcrossconnectionsbetweenrawandpasteurizedlines,betweenproductlinesand
cleanedinplace(CIP)circuits.
2. Inspectthesweetwatersystemandanyequipmentthatutilizessweetwaterforleaksandcracks.
Monitorthewaterforharmfulcontaminants.
3. Whenalterationsaremadeintheprocesspipingorequipment,changetheblueprintstoreflectthose
alterations.
4. Aspartofaroutinepreventativemaintenanceprogramexamineairvalves,screens,gaskets,seals,o
rings,andothermetal,rubberandplasticpartsonprocessingequipmentforwear.
5. Changethefiltersontheairblowsystemfrequently.
6. Useextremecautionwhenreworkingproducts.
a. Ensurethatallreclaimedproductshavebeenpasteurizedbeforereuse.b. Makecertainthatreclaimedproductisnotusedinthesamelinesorprocessingequipmentas
pasteurizedproductunlesstheyhavebeencleanedandsanitizedbetweenuses.
c. Donotreclaimproductsfromdamagedordirtycontainers.
d. Donotreclaimproductsthatarebeyondthenormalshelflife.
e. Donotreclaimproductsthathavebeenheldatelevatedtemperatures.
f. Donotreclaimproductsthathavebeenexposedtochemicalorbiologicalcontamination.
ALLERGENCONTROLPROCEDURES:
1. Utilizeproductandingredientlabels.
a. Ingredientlabels
identifying
all
allergenic
foods
must
be
on
all
containers
offered
for
sale.
The
precautionarycontainsstatementmustbeclearlyvisibleaftertheingredientstatement.
b. Recordallingredientsandtheirlotnumberontherecordsofmanufactureaswellasthelot
numbersofallfoodcontactpackagingmaterials.
c. Datecodingmustbeshownonallproducts.
d. Ensurethatpackaginglabelsandingredientlabelsmatch.
e. Allnewproductsandingredientsmustbereviewedforfoodallergensbeforetheirinitialuse.
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SSOP:006.002 EffectiveDate: 11/27/06
Supersedes SSOP: 006.001 EffectiveDate: 07/20/04
SANITATIONSTANDARDOPERATINGPROCEDURELabeling,Storage,andUseofToxicChemicals
INTRODUCTION
Toxicchemicalsareroutinelyusedinallaspectsofthefoodmanufacturingprocess. Properlabeling,
storageanduseofthesechemicalsminimizethechanceoffinishedproductcontaminationaswellasenhance
employeesafety.
MATERIALS
1. Supplies
a. Gloves
b. Goggles
c. Spillcontainmentsupplies2. Hazards
a. Chemicalscancausedamagetoskinandeyes.
b. Chemicalsusedinthemanufacturingandsanitationprocessesareapprovedforuseinthefoodindustry.
PROCEDURE
1. Labeling:
a. Allchemicals,includingmixedchemicals,shouldbeproperlylabeled.
b. ChemicalwastesshouldbelabeledwithredtagssuppliedbyEnvironmentalHealthandSafety
(EHS).
2. Chemicalstorage:
a. Chemicalsshouldbestoredandhandledinanareathatisdry,wellventilated,andseparatefrom
foodhandlingareas.
b. Allchemicalsaretobestoredsothatincompatiblesarenotnexttoeachother.
c. Chemicalwastesshouldbestoredinprimarycontainersthatarecompatiblewiththewasteand
leakproof. Theseprimarycontainersshouldbeheldinsecondarycontainmentinanapproved
accumulationarea.
d. Stored
chemicals
must
be
inventoried
annually.
e. ChemicalsnolongerinuseorpasttheirexpirationdatemustbemanifestedtoEHSfordisposal.
3. Chemicalusage:
a. Chemicalagents,includingdetergentsandsanitizers,shouldbeusedinamannerthatprevents
contaminationoffood,packagingmaterials,andfoodcontactsurfaces.
b. Chemicalsshouldbemixedandstoredinclean,labeledcontainers.
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4. Training:
a. Chemicalsshouldbehandledbyproperlytrainedpersonnel.
b. Within90daysofhire,allemployeesthatwillworkwithchemicalsarerequiredtoattendan
initialtrainingprovidedbyEHS. Annualrefreshersforthattrainingaremandatory.
c. MaterialsafetydatasheetsforthechemicalscurrentlyinusearelocatedintheCIProomorthey
canbe
accessed
on
the
internet.
RECORDKEEPING
1. Chemicalandhazardouswastehandlingtrainingrecordswillbemaintained.
2. Recordsoftheannualchemicalinventorywillbemaintained.
3. Awastereviewlogwillbemaintainedateachaccumulationarea.
REFERENCES
1. PennStatesEnvironmentalHealthandSafetyOffice
a. 6Eisenhower
Parking
Deck
b. 8148656391
c. Fax:8148637427
d. www.ehs.psu.edu
2. Materialsafetydatasheets
ThefollowingindividualisresponsibleforimplementationofthisSSOPandhastheoverallauthorityonsite:
Name:____________________________Title:__________________________Date:_______________
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Penn State Berkey Creamery Juice HACCP 2010
Page24of27
SSOP: 007.002 EffectiveDate: 11/27/06
Supersedes SSOP: 007.001 EffectiveDate: 07/15/04
SANITATIONSTANDARDOPERATINGPROCEDUREControlofEmployeeHealthConditions
INTRODUCTION
Goodmanufacturingpractices(GMPs)areestablishedbytheFoodandDrugAdministrationanddetailed
intheCodeofFederalRegulationstoprotectagainstcontaminationoffood. GMPsshallbefollowedbyall
Creameryemployees,students,andvisitors.
MATERIALS
1. Uniformsorlabcoats
2. Shoesorboots
3. Gloves
4. Hairandbeardrestraints
HYGIENICPRACTICES
1. Handsaretobethoroughlywashedwithsoapandwarmpotablewateranddriedatthefollowingtimes,andas
needed:
a. Whenreportingtowork
b. Afterabreakperiod
c. Aftersmoking,
eating,
or
drinking
d. Afterusingtoiletfacilities
e. Atotherappropriatetimesasneededtomaintaingoodsanitation
2. Eating,drinking,andgumchewingareprohibitedinfoodprocessingareas.
3. Properhairrestraintsmustbeworn
a. Hairrestraintmustcoverentirehead,includingthefrontandback
b. Beardrestraintsmustbewornbyallemployeeswithmorethanonedaysgrowthoffacialhair,
includingbeards,goatees,andsideburns.
c. Mustachesthatgrowbelowtheliplinemustbecoveredwithabeardrestraint
4. Fingernailsmustbeproperlygroomed;clean,cuttoanappropriatelength,withnopolishorartificial
nails.
5. Nowatchesorjewelry,exceptweddingringswithoutsets,arepermittedintheprocessingrooms.
6. Smokingand
the
use
of
other
tobacco
products
are
prohibited,
except
in
designated
outdoor
areas.
7. Cleanuniformsaretobewornatthestartofeachshift,andleftonthepremisesattheendofeachshift.
a. Uniformshirtsandlabcoatsmusthavesnapclosuresandnopocketsabovethewaistline.
b. Shoes/bootsmustremainonthepremisesandsanitizedinafootbathwhenappropriate.
c. Hats/bandanasthatarewornoverhairrestraintsmustbecleanandremainonthepremisesat
theendoftheshift.
8. Glovesusedinfoodhandlingshallbemaintainedinanintact,cleanandsanitarycondition. Theyshould
bemadeofanimpermeablematerial.
9. Personalbelongingsandstreetclothingshouldbestoredinanareaseparatefromfoodhandlingareas.
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INFECTIOUSDISEASEPOLICY
1. Employeesaffectedwithanydiseasecapableofbeingtransmittedtoothersthroughthecontaminationof
food,foodcontactsurfaces,orfoodpackagingmaterialsshallbeexcludedfromanyoperationswhich
maybeexpectedtoresultinthecontaminationoffinishedproductsuntiltheconditioniscorrected.
2. Personnelshall
report
such
health
conditions
to
their
supervisors.
INJURY/OPENWOUNDPOLICY
1. Employeeswithopensores,bleedingcuts,burns,orskininfectionswillnotbepermittedintheprocessing
rooms.
2. Somehandinjuriesmaybecoveredwithdisposablegloves,providedhandwashingproceduresare
followed.
CONTROLLEDACCESSPOLICY
1. Accessof
personnel
and
visitors
to
processing,
packaging,
and
finished
product
storage
areas
should
be
controlledtopreventcontamination.
2. Allpersonnelandvisitorsmustabidebytheemployeegoodmanufacturingpracticeslistedinthesections
above.
3. Allnecessaryprecautionsneedtobetakentopreventcontamination,includingtheuseoffootandhand
sanitizingsystems.
PERSONNELSAFETYPROGRAM
1. OSHArequirementsforconfinedspacesallowaccessbyemployeestoconfinedspaces,whennecessary,
formattersrelatedtotheoperationoftheprocessingfacility.
2. OSHA
rules
on
injury
protection
include
the
installation
of
devices,
such
as
guards
and
shields,
to
protect
personnelfrominjury. Hearingprotectioninareaswithhighlevelsofoperationalnoisewillreduce
hearingrelatedinjury.
3. Interiorairqualityrequirements. Adequateventilationandproperstorageofchemicalswillprevent
unnecessaryairborneexposuretohazardousmaterials.
REFERENCES
1. CodeofFederalRegulations
a. Title21,Volume2,Parts100169 (mostrecentrevision)
2. EPAandOSHAregulationsrelatedtopersonnelsafety.
3. PennStatesEnvironmentalHealthandSafetyOffice
a. 6EisenhowerParkingDeck
b. 8148656391
c. Fax:8148637427
d. www.ehs.psu.edu
ThefollowingindividualisresponsibleforimplementationofthisSSOPandhastheoverallauthorityonsite:
Name:____________________________Title:__________________________Date:_______________
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8/2/2019 Creamery Juice HACCP Plan
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Penn State Berkey Creamery Juice HACCP 2010