creamery juice haccp plan

8/2/2019 Creamery Juice HACCP Plan

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Penn State Berkey Creamery Juice HACCP 2010

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Berkey Creamery

JuiceHACCPPlan

EditedMay,2010.

By:

BenjaminThomas


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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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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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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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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



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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Name:____________________________Title:__________________________Date:_______________


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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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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


3. Conebottomprocessorandpasteurizedstoragetank(PT6)

a. TheconebottomprocessorandPT6aresanitizedpriortousewithanacidsanitizer.

b. Followinguse,

the

residual

product

is

rinsed

out

with

water.

c. Thedoorgasket,filllines,andexteriorsurfacesarehandwashedwithachlorinatedalkaline


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.


Name:____________________________Title:__________________________Date:_______________


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SupersededSSOP:003.002 EffectiveDate: 11/27/06


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.


Name:____________________________Title:__________________________Date:_______________


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Page19of27

SSOP:004.002 EffectiveDate: 11/27/06


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.


Name:____________________________Title:__________________________Date:_______________


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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


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


Name:____________________________Title:__________________________Date:_______________


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Page24of27



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


Name:____________________________Title:__________________________Date:_______________


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creamery juice haccp plan

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