THE DESIGN OF HACCP PLAN FOR A SMALL-SCALE CHEESE PLANT

By
Mengyu Zhao

A Research Paper
Submitted in Partial Fulfillment of the
Requirements for the
Master of Science Degree
In

Food and Nutritional Sciences

Approved: 2 Semester Credits



Dr. John Dzissah


The Graduate School
University of Wisconsin-Stout
May 2003
ii

The Graduate School
University of Wisconsin Stout
Menomonie, WI 54751

ABSTRACT

Zhao Mengyu
(Writer) (Last Name) (First Name) (Initial)
The Design of a HACCP Plan for a Small-scale Cheese Plant
(Title)
Food and Nutritional Sciences
(Graduate Major)
John Dzissah May, 2003 53
(Research Advisor) (Date) (No. of Pages)
Publication Manual of the American Psychological Association (APA)
(Name of Style Manual Used in this Study)

Hazards analysis critical control points (HACCP) was developed as a
management tool to provide a more structured approach to control identified
hazards. It was first developed for the US manned space program to provide
pathogen-free food. This is now widely used in the food industry to ensure safe
food was produced for the consumer. The purpose of this study is to modify the

iii
generic HACCP model for cheese production based on actual conditions in this
cheese plant. A specific model will be developed to boost the safety and quality
of cheese products in this plant.
The preservation of raw milk during cheese production was considered
to be safe. However, the spread of some diseases by unsafe cheese products
reported makes it important to pay attention to the potential contamination in
cheese production which could cause hazards to human health. HACCP is most
effective when it is plant-specific and product-specific. However, the generic
HACCP models have not been applied in most of the small-scale cheese plants.
To ensure the food safety in those plants, based on the generic HACCP model
this study is pursued to design a specific HACCP model to be suitable in a small-
scale cheese plant in western Wisconsin.











iv

ACKNOWLEDGEMENTS

Sincerely thank John Dzissah, my research director, for his professional
direction and time to help me complete this study

In addition, deep thanks to Michelle Stewart, the operations director in
the small-scale cheese plant, who provided the opportunity to work at their plant.

Finally, I want to especially thank Stephanie Olsen, who helped to
proofread my report.













v
TABLE OF CONTENTS

Page
Abstract ................................................................................................. ii
List of Tables ........................................................................................ vii
List of Figures ....................................................................................... vii
CHAPTER ONE: INTRODUCTION
Introduction ........................................................................................... 1
Statement of study ............................................................................... 3
Needs for the study .............................................................................. 3
Objectives ............................................................................................. 3
Significance of the study ....................................................................... 3
Limitations of the study ......................................................................... 4
FDA definitions ...................................................................................... 4
Other definitions .................................................................................... 5
CHARPTER TWO: LITERATURE REVIEW
Introduction ........................................................................................... 7
Necessity for HACCP ............................................................................ 7
History of HACCP ................................................................................. 8
Advantages of HACCP ......................................................................... 10
Developing of HACCP .......................................................................... 11
Cheese and HACCP ............................................................................. 12
Cheese making ............................................................................... 12

vi
HACCP on cheese .......................................................................... 16
CHARPTER THREE: RESEARCH DESIGN
Introduction ........................................................................................... 18
Subject selection and description........................................................... 18
Research method................................................................................... 18
Research approach................................................................................ 19
CHARPTER FOUR: REPORT OF FINDINGS
Introduction ........................................................................................... 30
Prerequisite program ............................................................................ 30
Product description ............................................................................... 32
List of ingredient and incoming material ................................................ 33
Flow diagram ........................................................................................ 34
Hazards identification ............................................................................ 36
Critical control points determination ...................................................... 37
HACCP control chart ............................................................................. 40
CHARPTER FIVE: CONCLUTIONS AND RECOMMENDATIONS
Statement of the problem ...................................................................... 42
Method and procedures ........................................................................ 42
Findings and conclusions ...................................................................... 42
Recommendations ................................................................................ 43
REFERENCE ........................................................................................ 45



vii
List of Tables

Tables Page
3.1 Production Description Form ........................................................... 20
3.2 Raw Material and Potential Hazards Form ..................................... 21
3.3 Hazard Analysis Chart Form ........................................................... 23
3.4 Process Decision Matrix Form ........................................................ 27
3.5 HACCP Control Chart Form ............................................................ 27
4.1 Production Description .................................................................... 32
4.2 Hazards in Ingredient and Incoming Material Analysis Chart .......... 33
4.3 Material Decision Matrix .................................................................. 34
4.4 Hazard Analysis Chart .................................................................... 36-37
4.5 Process Step Decision Matrix ......................................................... 39-40
4.6 HACCP Control Chart ..................................................................... 41

List of Figures

Figures Page
3.1 CCP Raw Material Decision Tree ................................................... 22
3.2 CCP Process Decision Tree ........................................................... 25
4.1 Flow Diagram .................................................................................. 35



1
CHAPTER ONE
Introduction
Introduction
HACCP is an acronym for the Hazard Analysis Critical Control Point. It is
a system that was developed for assuring pathogen-free foods for the space
program by the Pillsbury Company, the U.S. Army, and the National Aeronautics
and Space Administration (NASA) in the 1960s. HACCP was used in the food
processing industry for low-acid canned food production in the 1970s. It provides
precise process control measures for each step of the entire food manufacturing
process. More recently, HACCP has been used in the meat and poultry industry
that is regulated by the United States Department of Agriculture (USDA). It is
also used in the seafood, juice and egg industries, which are regulated by the
Food and Drug Administration (FDA). Now, the FDA is considering developing
regulations for the dairy industry too (Bardic, 2001; Riswadkar, 2000).
In dairy industries, HACCP is already being applied as a quality control
program, from fluid milk to ice cream to cheese. Cheese is a product that
preserves raw milk. Due to the high acidity (low pH value) in the cheese-making
process, the pathogens in the milk are killed. However, in cheese manufacturing,
problems associated with the presence of Listeria monocytogenes, Salmonella
enteritidis, Staphylococcus aureus, Escherichia coli and others have been
documented. The traditional quality testing and inspection used in the cheese
factory is applied to the product once a problem presents itself. It is thus difficult
to get 100% product inspection because of human error, obtaining sufficient

2
samples and so on. HACCP was originally developed as a zero defects
program and considered to be synonymous with food safety. It is a
straightforward and logical system that uses preventative action to address
potential microbiological, chemical and physical hazards that are identified in the
process. HACCP is a science-based system used to ensure that food safety
hazards are controlled to prevent unsafe food from reaching the consumer
(Bardic, 2001; Mortimore & Wallace 1997; Morris, 1997; IFST, 1998; Smukowski,
1996). HACCP is applied to the following:
1. Identify where hazards occurs along the process
2. Establish a control and monitoring process
3. Document all activities
4. Ensure continuity in preventative measures
(Mortimore & Wallace 1997)
Most large cheese manufactory companies have implemented HACCP
into their quality control systems in order to produce safe and good quality
product. However, seldom do small-scale cheese plants implement their own
HACCP plans. HACCP is a plant-specific and product-specific quality system
(Morris, 1997). To boost the quality of their cheese products, it would be of great
benefit to small-scale cheese plants if they develop and implement HACCP plan
based on their specific productions.




3
Statement of the study
The purpose of this study is to design a HACCP plan model for a small-
scale cheese plant in western Wisconsin. The model is modified from several
generic HACCP models. This study started in the fall semester, 2002. The
researcher worked in the plant, made observations of the plant environment, and
discussed potential hazards with the cheese maker and the operation director in
order to develop the specific HACCP model.
Needs for the study
This study is specifically designed for a small-scale cheese plant that
was just restructured and needs a better quality control system to produce
quality, safe cheese. The HACCP model can be applied in the plant to replace
the traditional inspection and quality procedure in order to prevent the hazards in
the cheese product.
Objectives
1. To evaluate the current methods of analysis on hazards that appear
during the processing and control procedures used in the plant.
2. To set up a specific HACCP plan for this small-scale cheese plant.
3. To document the HACCP plan in order to demonstrate the
effectiveness of its application.
Significance of the study
A brief and specific HACCP plan model will be developed in this study. It
is the first HACCP plan to be developed based on the actual conditions in this

4
small-scale cheese plant. It is a good start for a small plant, which has limited
resources and capital to perform the HACCP model as its quality control system.
The small cheese maker is more acutely affected by the consequences of
unsafe product. The HACCP model in this study is planned to prevent hazards
that could appear during the processing in this plant. It is a more efficient and
cost effective quality control tool for the small cheese maker.
Limitations of this study
This study is limited to the researchers time and the working experience
in cheese plants.
FDA Definitions (2001):
HACCP (Hazard Analysis Critical Control Point): A system designed to
identify, evaluate, and control of the potential food safety hazards.
HACCP Plan: The written document to describe the procedures based on
the principles of HACCP and specific conditions.
Hazard: A biological, chemical, or physical agent that is reasonably likely
to cause illness or injury in the absence of its control.
Contamination: exposure of food products to hazards, which can cause
illness, disease, or even death.
Prerequisite Programs: Procedures, including Good Manufacturing
Practices that address operational conditions providing the foundation for the
HACCP system.


5
Critical Control Points (CCPs): points in the process where hazards can
occur and controls can be applied to prevent or eliminate a food safety hazard or
reduce it to an acceptable level.
Critical Limit: A maximum and/or minimum value to which a biological,
chemical, or physical parameter must be controlled at a CCP to prevent,
eliminate, or reduce to an acceptable level the occurrence of a food safety
hazard.
Monitor: To conduct a planned sequence of observations or
measurements to assess whether a CCP is under control and to produce an
accurate record for future use in verification.
Corrective Action: Procedures followed when a deviation occurs.
Verification: Those activities, other than monitoring, that determine the
validity of the HACCP plan and that the system is operating according to the
plan.
Other Definitions
Good Manufacturing Practice (GMP): GMP is part of quality assurance
which ensures that products are consistently produced and controlled to the
quality standards. It is based on the knowledge and skills throughout the food
system, from raw materials, through processing of the consumer products and
distribution.
Laboratory Accreditation: laboratorys quality system conforms to the
requirements of an appropriate standard and of a laboratorys technical
competence to perform specific tests or calibrations

6

ISO 9000: ISO 9000 is a series of standards to define, establish, and
maintain an effective quality system for manufacturing and service industries.
Statistical Process Control Techniques: Statistical process control (SPC)
is scientific methods for analyzing data and keeping the process within certain
boundaries.



















7
CHAPTER TWO
Literature Review
Introduction
This chapter will discuss the necessity for and the history of HACCP as
well as the studies of the application and principle of HACCP. It will conclude with
a report of findings of the significance of HACCP on cheese processing.
Necessity for HACCP
According to a 1996 U.S. Dept. of Agriculture (USDA) report, food-borne
microbiological contamination in the U.S. causes an estimated 9,000 deaths and
33 million human illnesses annually. The cost of treating these human illnesses
and the subsequent loss in productivity is estimated to be $9.3 to $12.9 billion
annually (Riswadkar, 2000).
Recent headlines have reported food safety problems. Such as, AP-
Detroit reported: "Hot dogs blamed for Listeria outbreak" in June 1999; New York
Times reported: "12th death is linked to tainted meat at plant" on Jan. 27, 1999;
and CNN reported: "Armed with E-coli horror stories, consumer groups demand
safer meat" on Nov. 10, 1999 (Riswadkar, 2000).
Consumer expectations about food quality and safety have risen,
prompting food processors to seek systems and programs that improve food
safety.
Traditional quality assurance programs and facility inspections have
proven to be inadequate in controlling many food-borne illnesses. Therefore,
Food and Drug Administration (FDA), USDA and other food regulatory agencies

8
are seeking alternative approaches that will effectively and comprehensively
evaluate a food plant's ability to produce consistently safe and high-quality foods.
(Riswadkar, 2000)
The HACCP system is one such alternative, which focuses on identifying
and preventing hazards rather than relying on intermittent checks of
manufacturing processes and random sampling (Riswadkar, 2000).
History of HACCP
HACCP was developed by the Pillsbury Company along with NASA in the
1960s. It was originally developed as a microbiological safety system to ensure
food safety for astronauts. At that time most food safety and quality control
systems were based on end product testing, which is an inefficient method due to
product waste. Therefore, a preventative system needed to be developed to give
a high level of food safety assurance (Bardic, 2001; Bennet & Steed, 1999;
Mortimore & Wallace, 1997).
The HACCP approach was based on the engineering system, Failure,
Mode and Effect Analysis (FMEA). This system identified potential problems at
each operational stage and proposed solutions to such problems before
deploying effective control mechanisms (Mortimore & Wallace, 1997).
Like FMEA, HACCP looks for hazards, but in the interest of product
safety. Control and management systems are then implemented to ensure that
the product is safe for the consumer (Mortimore & Wallace, 1997).
Originally, HACCP was based on the following principles:

9
1. Comprehensive hazard analysis and risk assessment.
2. Determination and identification of critical control points (CCPs).
3. Monitoring of CCPs.
(Riswadkar, 2000, P33-34)
Subcommittees of both the National Conference on Food Protection and
National Academy of Sciences recommended that the HACCP approach be
adopted by both the U.S. food industry and other regulatory agencies in 1986.
This led to the formation of the National Advisory Committee on Microbiological
Criteria for Foods (NACMCF) in 1987. This committee expanded the HACCPs
original principle to include the following seven principles now widely accepted as
the standard (Riswadkar, 2000, P33-34):
1. Conduct hazard analysis and risk assessment.
2. Identify critical control points in food preparation.
3. Establish critical limits for each CCP.
4. Establish procedures for monitoring the CCPs.
5. Establish corrective action protocol for each CCP.
6. Establish procedures for effective recordkeeping.
7. Establish procedures for an effective verification (audit).
These principles allow safety and quality to be built into each step within
the process rather than focusing on the final step, the finished product. Even
potential consumer abuse and misuse is addressed by HACCP principles.
A systematic hazard analysis is used to identify critical control points
(CCPs) at each step of the process. These points must be controlled in order to

10
ensure food safety and prevent food-borne illnesses. With HACCP in place, a
food processor can identify and monitor specific food-borne hazards that are
microbiological, chemical or physical in nature. Microbiological hazards are
bacterial, viral, or enteric and parasitic organisms. Chemical hazards include
naturally occurring elements (such as mycotoxins from mold), toxic mushrooms,
plant toxins and chemicals added during food processing (such as pesticide
residues, food additives and lubricants). Though physical hazards occur less
frequently in food processing they do pose problems when fragments like glass,
stone, or metal are found in the product (Riswadkar, 2000).
Advantages of HACCP
HACCP is a systematic and scientific program. Based on its proactive
and preventative model, it gives consumers more confidence in product safety. It
focuses on identifying and preventing hazards from contaminated food by
enabling the processor to focus on CCPs. It prevents inefficiency associated with
blanket sanitation measures. It permits more efficient and effective government
oversight, primarily because the recordkeeping tracks compliance with food
safety laws over a period rather than sporadic monitoring on any given day.
Finally, HACCP also helps food companies compete more effectively in the world
market (FDA, 2001; Dillon and Griffith, 1995).
Recently, the FDA (2001) established HACCP for the seafood and juice
industries. In 1998, USDA established HACCP for meat and poultry processing
plants. Most of these establishments were mandated to start using HACCP by
January 1999. Small-scale plants had until Jan. 25, 2000.

11
The FDA (2001) is considering establishing the HACCP as the food safety
standard in other areas of the food industry, including both domestic and
imported food products.
To determine the feasibility of such regulations, the agency is also
conducting pilot HACCP programs with volunteer food companies producing
cheese, frozen dough, breakfast cereals, salad dressing, bread, flour and other
products (FDA, 2001).
Developing of HACCP
HACCP should be especially developed to each specific product and for
each process of production. Some prerequisite programs should be set up first,
which help to simplify the critical control points in HACCP. Quality Audit (QA)
/Quality Control (QC) programs, sanitation programs, microbiological analysis,
preventative-maintenance programs, employee training programs, Good
Manufacturing Practices (GMPs) and Standard Sanitation Operating Procedures
(SSOPs) are all prerequisites to HACCP (Morris, 1997).
The identification of CCPs in raw materials is important for developing
HACCP, since most of the hazards are brought in by raw materials. Many points
in food processing can be considered control points, but few are CCPs. Critical
Control Points should be established only at those points in a process where lack
of control is likely to result in a potential safety hazard. (Morris, 1997, n.p.).
Since there are many controlled operations in food processing, these CCPs can
be critical points steps or procedures during food processing. For example:
sanitation as a prerequisite program will get rid of some chemical hazards on the

12
utensils. The goal of these CCPs is to ensure that food safety hazard can be
prevented, controlled, reduced or eliminated. For example, the time-temperature
relation in pasteurization is a CCP (Riswadkar, 2000).
Another important area to consider is the Microbiological testing. This
test is ineffective in monitoring CCPs because of the time required to obtain
results, even with the rapid 48-hour systems recently developed (Morris, 1997).
Consequently, some specific temperature, time and pH controls have been used
in the cheese making process for a long time to control the quality of the product.
Therefore, those chemical and physical check points can be used to monitor the
critical hazards.
Cheese and HACCP
Attention has been drawn to the hazards to human health due to the
potential presence of pathogenic bacteria from the raw milk used in cheese
production. Recommendations have been given for safe production of cheese
applying Hazard Analysis Critical Control Point (HACCP) principles.
A. Cheese Making
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

13
is essential to aid in the expulsion of whey from the curd and largely determines
the final cheese moisture, flavor and texture (Hill, 2000).
According to several resources, the main procedures to make cheddar
cheese are as follows (Hill, 2000; Macrae et.al, 1993; Jenkins, 1996; Potter,
1995; Fox et al., 2000; Kosikowski and Mistry, 1997; Scott, 1986):
1. Pasteurize
Most cheese is produced from milk that has been pasteurized.
Pasteurization is one of the major critical control points in the cheese making
process. It helps to increase health to the consumer by destroying the pathogenic
micro-organisms present in the raw milk. High-Temperature-Short-Time (HTST)
pasteurization is widely used. This flow method system consists of heating
plates, a holding tube, a flow diversion valve, and time-temperature recording
charts. This method heats the milk to 72
o
C for at least 15 seconds.
2. Addition of the starter culture:
Cultures are the prepared inoculate of bacteria, yeast and moulds. They
have two purposes in cheese making which are to develop acidity and to
promote ripening. Lactic acid cultures contribute to both of these functions, while
numerous special or secondary cultures are added to help with the second
function.
The starters for cheddar are mesophilic homofermenative cultures of
Lactococcus lactis subsp. Lactis and cremoris. There is generally a ripening
period of 30-60 min depending upon the type of starter added.


14
3. Protein coagulation:
Casein is the major protein in milk. During cheese production, rennet, a
coagulating enzyme, is stirred into the milk. Under certain acid condition, rennet
then separates the casein from the whey and causes the individual cells of the
casein to clump together to form the gel network.
4. Cutting:
Proper cutting is extremely important to both quality and yield. The small
curd particles could be lost by the improper cutting and handling of the curd. Both
early cutting when the curd is fragile and late cutting when the curd is brittle
cause losses of particles. The curd is ready to cut if it breaks cleanly when a flat
blade is inserted at 45
o
angle to the surface and then raised slowly. Curd size
has a great influence on moisture retention, so the cutting wire should be chosen
carefully.
5. Cooking:
The cooking and stirring will cause an increase in the acidity. Therefore,
the moisture, lactose, acid, soluble minerals and salts, and whey proteins will be
expelled. After cutting, the curd is gently stirred in the whey, and the temperature
is raised from 30 to 38C over a period of 45-60 min.
6. Drainage:
The whey is drained when the pH of the curd is 6.0. The curds are
allowed to settle; a strainer is inserted, the exit gate valve is opened, and the
greenish colored whey is diverted to a storage tank.


15
7. Cheddaring:
Cheddaring is used only for cheddar cheeses as a curd treatment to
achieve a particular texture for milling the cheese. The curds are matted for 15
minutes following complete whey removal. A longitudinal cut is made down the
middle of two trenched curd columns with a large bread knife. Horizontal columns
are then cut at intervals of approximately 25.4 centimeters (10 inches). The curd
blocks are spaced at about 2.5 centimeters (1 inch) apart, allowed to rest for 15
minutes and then turned over. This is repeated twice at 15 minute intervals with
all loose curds swept under the blocks. Individual blocks are piled double and
turned over every 15 minutes so that new surfaces are exposed. If necessary,
the blocks are piled three high for the last 30 minutes.
8. Milling:
Milling is a process of reducing the size of cheddared curd into small
pieces so that salt can be applied. Milling is done when the pH 5.2-5.4 is reached
for the draining whey.
9. Salting:
The purpose of salting is as follows: to inhibit the growth and activity of
pathogenic and food-poisoning microorganisms; inhibit the activity of various
enzymes in cheese; reduce the moisture of cheese; change cheese proteins
which influence cheese texture and protein solubility; and affect cheese flavor.
Cheddar cheese is salted with the dry salt. 1.5-2.0% salt is spread manually over
the milled curd.


16
10. Hooping and pressing:
The salted cheese was shaped into the metal hoops which are lined with
muslin cloth. During hooping, the curds are allowed to form a continuous mass.
Pressing the mass helps to form loose curd particles into a compact mass and
expel whey. The cheese is pressed overnight with low pressure initially and then
gradually increasing the pressure to 75 kPa. This is because initial high pressure
compresses the surface layer and traps moisture in the body of the cheese which
would be undesirable.
11. Ripening:
Cheese ripening exposes the prepared cheese to certain environmental
conditions (temperature, humidity and so on) for several months to several years
depending on the cheese type. The purpose is to break down the proteins, lipids
and carbohydrates (acids and sugars) which releases flavor compounds and
modifies cheese texture. Cheddar cheese is ripened at 2-12C for 3-12 months,
depending on the maturity required in the final product. The cheese is then cut
and packed in retail packs.
B. HACCP on Cheese:
HACCP principles have been written into the requirements of the UK Food
Safety (General Food Hygiene) Regulations 1995 and the Dairy Products
(Hygiene) Regulations 1995. The Institute of Food Science and Technology
(IFST) strongly supports: the application of HACCP-based systems for cheese
manufacture at all stages 'from farm to fork' (IFST, 1998, P119).

17
For the consistently reliable production of microbiologically safe cheese,
IFST considers the following measures important (1998, p.121):
1. A HACCP-based risk assessment and Good Manufacturing Practice
should be employed at all stages of production and handling, from the
farm to the consumer.
2. For those products where a risk assessment indicates a hazard from
pathogens in the raw milk, the milk should undergo full pasteurization
or a process of equivalent effect.
Developing a HACCP plan for the small-scale cheese plant can be
difficult. Therefore, this study will pursue a brief HACCP plan based on the actual
conditions in this plant.













18
CHAPTER THREE
Research Design
Introduction:
This chapter includes a description of the subject that was selected, the
research method and process that was used in this study and how this study was
approached by introducing the HACCP recordkeeping forms.
Subject selection and description:
This study was conducted in a small-scale cheese plant (less than 10
employees) in Wisconsin. This is an old plant which was being restructured to
include an effective control system to boost product quality and productivity.
The restructuring was aimed at expanding the companys market.
Consequently, the company plans for effective quality system to ensure safe and
good quality products.
Research method:
This study did not use quantitative research because quantitative
requires data analyzing. The purpose of this study was to design a HACCP
model not to implement it in the actual situation. Therefore, there is no statistical
data.
This study matched a qualitative approach because it provides depth and
careful scrutiny of the program situations, events, employee interactions and
observed behavior. It gives the intricate details of phenomena that are difficult to
convey with quantitative methods. Qualitative research is exploratory and open-
minded which is applicable to this study (Patton, 1987).

19
Research approach:
This research was done for a small-scale cheese plant. The researcher
designed a brief HACCP plan based on the setting and processing in this plant in
order to improve the cheese product quality. Based on the principle and several
existing generic models of HACCP, the recordkeeping forms of the model in this
study were designed in the following manner:
1. Prerequisite program
2. Product description.
3. List of product ingredients and incoming materials.
4. Process flow diagram.
5. Hazard identification.
6. Critical control points determination.
7. HACCP control chart.
1. Prerequisite program:
Prerequisite programs involve several steps and procedures to provide a
safe environment and condition for the production of cheese. These programs
are crucial to determine the critical control point. Without the programs, the
researcher needs to consider more hazards that are possible to the product from
outside of the process. The prerequisite programs for this small-scale cheese
plant are based on the building design, pest control, storage and transportation,
sanitation, water supply, equipment and personal hygiene.



20
2. Product description:
This part of the model gives criteria on how to describe the product
characteristics for the consumers. It is important that the consumers know how to
properly use and store the product (See: Table 3.1). All the details of the product
description provide the information on possible critical hazards that could affect
the quality and safety of the product. It helps the researcher to make the right
decision on how to prevent the possible hazards. For example, the cheddar
cheese is a ready-to-eat product; therefore, the pasteurization process is a
critical step in cheese making process.

Table 3.1: Production Description Form
(Canadian Food Inspection Agency, 2001)

1. Product Name
2. Important product characteristics
(Moisture, pH, salt, preservatives)

3. How it is to be used
4. Packaging
5. Shelf life
6. Where it will be sold
7. Labeling instruction
8. Distribution condition






21
3. List of ingredients and incoming materials:
Hazards are seldom created by themselves in processing. Most of the
hazards come from the ingredients and incoming materials. For example, the raw
milk contains harmful bacterial such as E.coli, Staphylococcus aureus,
Salmonella that could contaminate the end product. All the ingredients and the
possible microbiological (M), chemical (C) and physical (P) contamination or
hazards will be listed in Table 3.2.


Table 3.2: Raw Material and Potential Hazards Form
(Canadian Food Inspection Agency, 2001)


Main ingredient Other ingredient Packaging
Milk MCP Starter culture CP Cryovac MCP

The CCP decision tree will help to identify appropriate CCPs in the
process. Using a CCP Decision Tree promotes structured thinking and ensures a
consistent approach at every process step and for each hazard identified. It is a
flow of three questions. All three questions focus on analyzing the hazards in the
raw material and determining whether or not each hazard is a critical control
point. Using the decision tree will allow the producer to identify the potential
critical hazards in raw materials.



22
Figure 3.1: CCP Raw Material Decision Tree
(Mortimore and Wallace, 1997)

Q1. Is there a hazard associated with this raw material?

Yes No

Proceed
Q2. Are you or the customer going to process this hazard?
Out of the product?
No


Yes Sensitive raw
High level of control
required
CCP
Q3. Is there a cross-contamination risk to the facility or to
other products which will not be controlled?

Yes No

Proceed
Sensitive raw material
High level of control required
CCP


4. Process flow diagram:
The process flow diagram is made of a sequence of steps through the
whole process; a concise explanation of each step is given to describe how the
final product is made. It is used to document the production and distribution
processes and helps to identify hazards at each step. It includes the processes
from the raw material to the production procedure to the distribution. See sample
at Figure 4.1 in chapter four.


23
5. Hazard identification:
Hazard identification is helpful to identify potential microbiological,
chemical and physical hazards that may occur during each step of processing.
Microbiological hazards are pathogens or harmful bacteria introduced during
production. Another microbiological hazard stems from improper personal
hygiene. Chemical contaminants include the plant toxins and chemicals added
during food processing. For example, the excess detergent left on the just
cleaned equipment. A physical contamination is foreign material that could come
from incorrect personal handling or bad environmental conditions.
In the hazard analysis chart (Table 3.3), both the preventative measures
and the type of hazards are identified within each process step. The preventative
measures control the hazards by eliminating or reducing the occurrence of
hazards to an acceptable level.

Table 3.3: Hazard Analysis Chart Form
(Mortimore and Wallace, 1997)


Process step Hazard Preventative measure







24
6. Critical control points determination:
There are two parts in this section. The first part is the critical control point
(CCP) decision tree (Figure 3.2); the second part is the CCP decision matrix
(Table 3.4).
The CCP decision tree for the processing phase will help to identify
appropriate CCPs in the process. It is a flow of five questions that focus on
analyzing the hazards in the process and determining whether or not each
hazard is a critical control point.
















25
Figure 3.2: CCP Process Decision Tree
(Mortimore and Wallace, 1997)

Q1: Is there a hazard in this process step?
What is it?

Yes no not a CCP

Stop
Q2: Do preventative measures exist for the
identified hazard

No modify step, process or
product
Yes
Is control necessary at this step for safety? Yes

No not a CCP stop
Q3: Is the step specifically designed to eliminate
or reduce the likely occurrence of the hazard
to an acceptable level?

Yes

No


Q4: Could contamination occur at or increase to
unacceptable levels?


Yes no not a CCP stop


Q5: Will a subsequent step or action eliminate or
reduce the hazard to an acceptable level


Yes not a CCP stop critical
control
point


26
The five following questions are in the decision tree (Mortimore and
Wallace, 1997):
Question 1 identifies the hazards in a specific process step. To answer
this question, the researcher needs to think about the entire potential hazard in
this step. No one hazard should be neglected in this part. If there is a hazard
then go to the question 2.
Question 2 is to find out whether or not there is a preventative measure
for the identified hazard. The researcher should use the information in the hazard
identification section. If there are no preventative measures, the researcher
should ask if control is necessary at this step. If yes, the step, process or the
product needs to be modified. If this is a preventative measure, the process
moves to the question 3.
Question 3 is made for some special process steps, which are set up for
controlling the hazards; for example, pasteurization for the raw milk. If this
process step is designed to deal with the hazards, this process is a CCP. If not,
go on question 4.
Question 4 identifies the contamination involved in the process. The
researcher must combine the condition of the process and the possible hazards.
For example, does the environment of the process include hazards? Does the
personal action in this process include hazards? If the contamination could occur
at or increase to an unacceptable level, move to question 5.

27
Question 5 identifies a subsequent action that can eliminate the hazards.
If there is an action, this process step is not a CCP. If there is not one, it should
be a critical control point.
The CCP decision matrix lists all the answers (Yes/No) for every question
based on each hazard. The matrix provides space for the researcher to expand
why the hazard is a critical control point or not.

Table 3.4: Process Decision Matrix Form
(Mortimore and Wallace, 1997)

Process step and
hazard
Q1 Q2 Q3 Q4 Q5 CCP Notes

Y Y N Y Y N
7. HACCP control chart:
The HACCP control chart (Table 3.5) is made based on the CCPs in the
processing. For each CCP, the identified hazards and preventative measures will
be listed in this chart. In addition, the critical limits, monitoring, corrective action
and responsibility will be summarized in this chart. All the information is well
organized and documented for a HACCP plan. It helps the company easily
manage all the information.

Table 3.5: HACCP Control Chart Form
(Mortimore and Wallace, 1997)
Process
step
Hazards Preventative
measure
Critical
limits
Monitoring
procedure
Monitoring
frequency
Corrective
action
Responsib
ility


28
Critical limits are the boundaries for controlling each hazard based on the
preventative measure. Critical limits are the absolute tolerances of the hazard
levels to ensure safety. The researcher needs to fully understand the safety
criteria at each CCP so that the proper critical limits can be provided. It is
important that a measurable factor accompanies the critical limit so that it can be
routinely monitored. Some factors that are commonly used as critical limits
include temperature, time, pH, moisture or salt concentration and titratable acidity
(Mortimore and Wallace, 1997).
To demonstrate a process is operating within the critical limits,
monitoring is used to measure or observe a CCP. The procedure is important to
ensure that the process is under safety control. Monitoring is more effective with
repeated inspection and testing. The data should be recorded continuously too.
Some discontinuous systems are also used in monitoring. The frequency of
monitoring shows how often monitoring needs to be provided. It depends on the
type of CCP and monitoring procedure (Mortimore and Wallace, 1997).
When a deviation from a critical limit occurs at a CCP, a corrective action
needs to take place, according to HACCP principle 5. The researcher should also
incorporate corrective actions that will prevent deviation at the CCP. The
corrective actions should be specified on the HACCP plan. Those actions should
focus on both the CCP and the specific circumstances and environment of the
processing (Mortimore and Wallace, 1997).
The responsibility should be considered both in monitoring and corrective
action. The most important issue with responsibility is ensuring it is properly

29
assigned. An operator in processing needs to know the necessary procedures
and the correct way to follow them. It is also important to define which individuals
are responsible for documenting and certifying the corrective action procedures.
This information will be crucial in verifying that the required action has been
taken. This is particularly important for legal issues (Mortimore and Wallace,
1997).


















30
CHAPTER FOUR
Report of Findings
Introduction
Based on the principle of the HACCP and several generic models, the
HACCP model was designed in chapter three. In this chapter, the designed
model is further modified to suit the real situation of the cheese plant to boost the
quality control system in order to produce safe and quality end products.
Prerequisite program
There are several programs used in this plant:
1. Building design:
The building designs are the premises for the production. It should be
noted whether the paint on the walls and ceiling is or is not peeling; the ceiling is
or is not leaking; the floor is sloped for liquid to drain and the door is self-closing.
It should be routinely cleaned and sanitized by a professional housekeeper. The
floor should be cleaned daily.
2. Pest control:
The pest control activities should be contracted to professional in food
industries. The UV light could eliminate the flies and the mice trap could
eradicate the mice.
3. Storage and transportation:
The specific conditions of the store room need to provide appropriate
temperature and humidity for the raw materials and the final products. Daily
inspection of the conditions could ensure a consistent environment to prevent the

31
hazards and produce quality products. Proper transportation equipment should
be used and the proper environmental conditions should be monitored for each
batch.
4. Sanitation:
The sanitation facilities should be properly set up to eliminate possible
hazards. The sanitation tube connected with the facilities should be long enough
to reach all the areas that need to be sanitized. The strength of the chlorine
solution should be 200ppm; daily check is required. The sanitation should be
used on all the equipment, containers and tools in the process. Sanitation should
be part of the personal hygiene too.
5. Water supply:
Potable water should be used in the process. The water potability testing
should be verified and recorded every half year. The filter for the water needs to
be checked monthly.
6. Equipment:
All the equipment needs to be checked routinely to ensure a smooth
running system. The equipment should be operating properly and should be free
of cracks, rust and dents.
7. Personal hygiene:
The employee should be well-trained on the personal hygiene. The
supervisor should conduct checks daily. The employee needs to wear a hat or a
hair net while working and needs to wash and sanitize his/her hands before
working. The employee should apply appropriate action based on the personal

32
hygiene requirements in the cheese making area. The employees must also be
free of disease.
Product description
Based on the FDA regulation, the optimum moisture is 39%. Cheddar
cheese belongs to hard cheese category with the moisture contents ranging from
30-45%. The moisture should be measured for each batch in this plant.
Measurement of the pH and the salt concentration is specifically set up for this
cheese plant to produce the best quality cheddar cheese. Cryovac is used as
packaging material, which meet the safety requirements for this plant. The shelf
life of this product could be longer than one year because it is a low acid food
and this particular cheese is made with pasteurized milk. This ready-to-eat
product will be sold retail and must be distributed in a refrigerated condition and
the label needs to instruct the consumers to refrigerate the product.

Table 4.1: Product Description
(Modified from Canadian Food Inspection Agency, 2001)

1. Product Name Cheddar Cheese
2. Important product characteristic
(moisture,pH, salt, preservatives)
Hard cheese
Moisture%: 30-45%
PH: 5.2-5.4
Salt: 1.5 -2.0%
3. How it is to be used Ready to eat
4. Packaging Cryovac, vacuum seal
5. Shelf life Several years
6. Where it will be sold Retail store
7. Labeling instruction Keep refrigerated
8. Distribution condition Refrigerated

33
List of ingredient and incoming material (Include Table 4.2 and Table 4.3)
In Table 4.2, MCP is representing the microbiological, chemical and
physical hazards in the raw material. The table also includes the preventative
measures for the hazards in each raw material. See detail in Table 4.2.

Table 4.2: Hazards in Ingredient and Incoming Material Analysis Chart:
(Modified from Canadian Food Inspection Agency, 2001)

Ingredient & material Hazards Preventative measure
Milk MCP Store < 4 C
Proper transfer equipments
Sanitize equipment
Proper personal hygiene and handling
Starter culture M Qualified product supply, store < -40 C
Rennet M Qualified product supply, store < 4 C
Salt MP Qualified product supply, store at Room
temperature
Proper personal hygiene and handling
Water MCP Supply quality water
Cryovac MCP Qualified product supply
The decision matrix is then filled out based on the answers given to the
questions from the decision tree (Figure 3.1). Four CCPs are found in the
material. The qualified products supply for starter culture and the rennet could
control the microbiological hazards in the production. As a qualified product, the
salt needs to be out of foreign material. The brand name of the packaging
material is qualified for cheese packaging. However, the quality of the products
produced in this cheese plant still need to be well-controlled to prevent all the
three types of hazards. Other hazards are control points that could be controlled
in a prerequisite program or other process. See detail in Table 4.3.

34
Table 4.3: Material Decision Matrix
(Modified from Mortimore and Wallace, 1997)

Raw material Q1 Q2 Q3 CCP? Notes
Milk
-M


-C

-p

Y Y N


Y Y N

N -- --

N


N

N
The raw milk is considered to associate with
hazards, such as salmonella. However, the
heat process: pasteurization will deal with
those hazards.

Prerequisite program: equipment and
sanitation
Filters for incoming raw material and during
pasteurization
Starter culture
-M

Y N --

Y

Qualified product supply is critical
Rennet
-M

Y N --

Y

Qualified product supply is critical
Salt
-M
-P

Y Y N
Y N --

N
Y
Prerequisite program: personal hygiene & food
storage
Quality product supply is critical
Water
-M


-C
-P

Y Y N


Y Y N
N -- --

N


N
N

The water is used to wash all the equipment
and adjust the moisture; those processes are
provided both before and after the heat
process.
Prerequisite program: quality water supply
Filter for water
Cryovac
-MCP

Y N --

Y

Qualified product supply is critical

Flow diagram
The flow diagram is specific for the cheese production in this plant. It is
made of four parts: raw material, processing, critical limits and adjustment. The
reason is the producer needs to check the condition of each step during
processing. If it is inside the critical limits, the process continues; otherwise the
process is stop and the proper adjustment is made. The adjustment is
determined based on the temperature, time and salt change. If the condition
cannot be controlled the product will be reject. See detail in Figure 4.1.

35
Figure 4.1: Flow Diagram


Raw material Processing Critical limits Adjustment

No
Yes

No
Yes

No
Yes

No

Yes

No
Yes




No
Yes

No
Yes




No
Yes




No
Yes



No
Yes



Storage
Culture
Adjust T & Ti
Cutting
Adjust T & Ti**
Cheddaring
Adjust T
Coagulation
Filling
Adjust T*
Pasteurization
72C 16s
32C
6C
Milling
Scalding
Stirring
Whey drainage
Adjust Ti
Milk
15000 lbs
Starter
2 cans
Rennet
40 mL per
1000lbs
30C 30 min
38C 30 min
38C 20 min
M%=30-45%
pH 6.6 30C 30 min
pH 4.8-5.4
4-6C
Adjust T & Ti
Adjust Ti
pH 5.2-5.4
Adjust Ti
Salting
Adjust T, Ti
Ripening
Moulding, pressing, wrapping
Adjust Salt, T & Ti
Storage, distribution
Salt
1.5-2.0%
* T: Temperature ** Ti: Time

36
Hazards identification
In Table 4.9, the preventative measures are provided for the hazards in
each processing step. All the control situations are set up under the requirements
in this plant to make safe and quality cheese. See details in the table.

Table 4.4: Hazard Analysis Chart

(Modified from Mortimore and Wallace, 1997)


Process step Hazards Preventative measure
Adding milk MCP
Proper equipment setting,
Sanitize all the transfer equipment
Pasteurization MCP
72C 16 sec,
Proper pasteurizer setting,
Sanitize all the equipment
Filling MCP
Heat to 32C,
Sanitize the milk tank, the stirring tools and the
thermometer,
Proper personal hygiene & handling,
Proper building setting (tank is without cover),
Pest control
Adding starter culture MP
Medium agitate
Proper personal hygiene & handling
Adding rennet MCP
pH 6.61 30C
Sanitize the container used for diluting rennet,
Proper personal hygiene & handling
Coagulation MP
30 min,
Stop stirring and take tools out,
Proper personal hygiene & handling
Cutting MCP
pH 6.57
Correct knife size for optimum curd size,
Sanitize the cutting tools and the cutters hands and
arms,
Proper personal hygiene & handling
Scalding M
38C 30 min,
Proper personal hygiene
Stirring MCP
38C 20 min,
Sanitize the stirring tool,
Personal hygiene and handling



37
Table 4.4: Hazard Analysis Chart (continue)

(Modified from Mortimore and Wallace, 1997)


Process step Hazards Preventative measure
Whey drainage MCP
pH=6.4
Sanitize all the tools,
Proper recycle whey setting,
Proper personal hygiene and handling
Cheddaring MCP
Consistently monitor pH during cheddaring
Sanitize the knife,
Proper personal hygiene and handling
Milling MCP
pH=5.35 (5.2-5.4)
Sanitize the milling machine,
proper personal hygiene and handling
Salting MCP
1.5-2.0% salt,
Moisture content is optimum at 39%,
Sanitize the salt container and the stirring tools,
Supply quality water,
Proper personal hygiene and handling
Moulding MCP
Sanitize the moulding container and cloth,
Proper personal hygiene and handling
Pressing MP
Proper pressure at 75kpa,
Proper whey drainage setting,
Proper personal hygiene and handling
Wrapping MCP
Proper vacuum machine setting,
Sanitize the container, scale and tools,
Proper personal hygiene and handling
Ripening MP
Proper building setting,
Proper storage condition setting,
Pest control

Critical control points determination
Based on the process decision tree, there are seven CCPs identified.
See detail on Table 4.5. All those seven CCPs are determined based on the
following requirements in this plant.
1. The time and temperature of the pasteurizer is the most critical control
point in the cheese making. Most of the pathogens are eliminated or reduced to
the safety level.

38
2. The filling temperature is critical because it can provide the best situation
for the starter culture to grow and at the same time, restrain the growth of the
pathogens.
3. The supply and the amount of starter culture used in the production is the
most guarded secret for a plant. Starter culture is used to produce acid before
adding rennet. The rate of adding starter and rennet is very critical for the safety
and also the flavor and aroma for the cheese. See detail in Table 4.6. It can be
controlled by pH before adding rennet. The rate of agitation is very critical in this
plant according to the producer. If the rate is too high, the air in the milk will
interrupt the coagulation; if the rate is too low, the starter cannot be mixed well in
the milk.
4. The time of coagulation controls how well the gel forms before cutting. If
the gel is cut early, some proteins will be lost and the pathogens will grow.
According to the producer, if the stirring tools are kept in the vat during
coagulation, the proteins will not be formed into a gel network. It is very critical for
the production in this plant.
5. The final pH is critical to control the growth of the pathogens. The low
value of the pH inhibits pathogen growth and guarantees safe cheese.
6. The scalding and stirring time and temperature could influence the cheese
to get the desired pH and moisture.
7. The rate of salt is very critical because under-salting will affect acid but
over-salting will allow the growth of the pathogenic bacteria.


39

Table 4.5: Process Step Decision Matrix

(Modified from Mortimore and Wallace, 1997)

Process step and
hazard
Q1 Q2 Q3 Q4 Q5 CCP Notes
Pasteurize
-M

-C
-P

Y Y Y

Y Y N Y Y
Y Y N Y Y

Y

N
N

Correct temperature and time kill the
vegetative pathogens
Prerequisite program: sanitation
Prerequisite program: proper equipment
running & personal hygiene training
Filling
-M

-C
-P

Y Y N Y N

Y Y N Y Y
Y Y N Y Y

Y

N
N

Correct temperature is critical for starter
growth
Prerequisite program: sanitation the
transfer equipment and milk vat
Prerequisite program: proper personal
hygiene
Adding starter &
rennet
-M
-C
-P


Y Y N Y N
Y Y N Y Y
Y Y N Y N


Y
N
Y
Proper additional rate of starter and
rennet is critical
Prerequisite program: personal training
Prerequisite program: sanitation
Proper amount of agitate is critical
before coagulation
Prerequisite program: personal hygiene
Coagulation
-M
-P

Y Y N Y N
Y Y N Y N

Y
Y

Proper coagulation time is critical
The foreign material such as the stir tool
is critical for protein coagulation
Cutting, Scalding &
Stirring
-M
-C
-P


Y Y N Y N
Y Y N Y Y
Y Y N Y Y


Y
N
N


Correct temperature and time are
critical
Prerequisite program: sanitation
Prerequisite program: personal hygiene
training
Cheddaring
-M
-C
-P

Y Y N Y Y
Y Y N Y N
Y Y N Y N

N
N
N

Prerequisite program: personal hygiene
Prerequisite program: sanitation
Prerequisite program: personal training
Milling
-M
-C
-P

Y Y N Y N
Y Y N Y Y
Y Y N Y Y

Y
N
N

Proper pH before milling is critical
Prerequisite program: sanitation
equipments
Prerequisite program: proper running of
equipments & personal training

40
Table 4.5: Process Step Decision Matrix (continue)

(Modified from Mortimore and Wallace, 1997)

Process step and
hazard
Q1 Q2 Q3 Q4 Q5 CCP Notes
Salting
-M
-C
-P

Y Y N Y N
Y Y N Y Y
Y Y N Y Y

Y
N
N

Proper amount of salt is critical
Prerequisite program: sanitation
Prerequisite program: personal training
Moulding, Pressing
& Wrapping
-M
-C
-P


Y Y N Y Y
Y Y N Y Y
Y Y N Y Y


N
N
N


Prerequisite program: personal hygiene
Prerequisite program: sanitation
Prerequisite program: personal training
Ripening
-M
-P

Y Y N Y Y
Y Y N Y Y

N
N

Prerequisite program: food storage
Prerequisite program: pest control
HACCP control chart
The HACCP control chart (Table 4.6) shows all the potential critical
hazards that can occur during processing in this small scale cheese plant. It is
the most essential part of the whole HACCP plan, which is the organization
analysis and documentation of the CCPs. (see detail in Table 4.6). The column of
the responsible will be filled out by the operator or the supervisor who is
responsible for the control. The steps that contain those CCPs will be
emphasized during production. The documentation of the HACCP plan which is
suitable for the conditions in this small-scale cheese plant will help to prevent and
eliminate those critical hazards in its production. Therefore, safe and quality
cheese products could be produced in this plant. The document also can be used
for improvement of a HACCP plan in the future.



41
Table 4.6: HACCP Control Chart

(Modified from Mortimore and Wallace, 1997)
Process
step
Hazards Preventative
measure
Critical limits Monitoring
procedure
Monitoring
frequency
Corrective
action
Responsi
bility
Raw &
packagi
ng
material

CCP # 1
Microbiological
chemical &
physical
contamination
Qualified starter
& rennet supply

Qualified
cryvoac supply
No
unqualified
material be
used

Apply supply
quality
assurance
Each
supply

Change
supplier

Operator
training


Pasteuri
zation

CCP #2
Survival of
pathogens such
asE.coli,
Staphylococcus
aureus, Bacillus
cereus, etc.
Pasteurizer
checks:

-check the heat
plate
-check the
temperature
controller
-check the flow
diversion

Temperature
set at 72C
Time set at
16 sec
Check
thermometer
and time
check
equipment is
properly
running
Supervisor
managing
and record
keeping
Each batch



Routinely



Each batch
Adjust the
temperature
And time by
setting the
equipment
well

Call the
engineer to
repair

Filling

CCP #3
Microbiological
contamination
Proper
temperature
setting

Temperature
set at 32C

Check
thermometer

Record
keeping
Each batch


Each batch
Adjust the
heater to
change
temperature


Adding
starter &
rennet

CCP #4
Microbiological
contamination





Physical
contamination
Proper
additional rate





Agitate properly

Starter: 2cans,
Rennet: 40 mL
per 1000 lbs
milk
pH is measured
at 6.6 before
adding rennet

Agitator set at
medium
Check the
additional rate
of the starter
and rennet &
pH
check the rate
of the agitator

Record
keeping
Each batch



Each batch
Applying more
testing on pH
Use active
starter culture

Adjust agitate
rate

Operator
training

Coagula
tion

CCP #5
Microbiological
contamination

Physical
contamination

Proper time
setting and
recording

Take the stirring
tools out of the
tank
Time is set at
30min

Tools prevent
coagulation
Check the
time and the
stirring tools

Record
keeping

Each batch


Each batch
Reject product

Operator
training



Cutting,
scalding
&
stirring

CCP #6
Microbiological
contamination

Proper time &
temperature
setting
Temperature
is set at 38C,
scalding for
30min and
stirring for
20min
Check the
temperature
and the time

Record
keeping

Each batch



Each batch
Adjust the
heater to
change
temperature

Operator
training

Milling

CCP #7
Microbiological
contamination


More
cheddaring time
control the pH

Use of an active
starter culture at
the correct
addition
pH is
measured at
5.2-5.4
Consistently
monitor pH
during
cheddaring

Supervisors
managing
and record
keeping
Each batch Reject product

Applying more
testing on pH

Operator
training


Salting

CCP #8
Microbiological
contamination

Correct level of
salt
Correct mixing
during salting

Salt%=1.5-
2.0%
Records and
testing

Each batch Incorrectly
salted curd
must not be
allowed to
progress



42
CHAPTER FIVE
Conclusions and Recommendations
Statement of the problem
The study designed a HACCP plan model for a small-scale cheese plant
to improve the safety and quality of its products.
Method and procedures
The form of this HACCP plan model was modified from several generic
HACCP models used in this study. The form is then further modified based on
the identified CCPs that were found from the observation and research that was
conducted in the plant.
Findings and conclusions
The model is developed step-by-step based on the seven principles of
HACCP system mentioned in the literature review. The prerequisite program was
provided to deal with some hazards before the production; therefore, to simplify
the HACCP plan. The product description was used to alert the consumer to the
potential hazards in the final products. Then, the potential control points of the
hazards appeared in both raw material and the process will be studied along with
the prevention measures. By answering the questions in the decision trees, the
critical control points were determined. Finally, the HACCP control chart was
developed to include components of several HACCP principles which are critical
limits, monitoring, corrective action and responsibility.
Eight CCPS were found in the production in this cheese plant. They are:
1. Qualified supply of starter, rennet and packaging material.

43
2. Proper pasteurization
3. Proper temperature of filling
4. Proper setting during adding starter and rennet
5. Proper setting during coagulation
6. Proper time and temperature during scalding and stirring
7. Proper pH for milling
8. Proper salting
From the literature review, HACCP is an improved system compared to
the traditional sampling and testing quality control. Not only because it is a
prevention instead of a reaction which reduces the risk of processing and selling
unsafe products; also because it is a cost-effective program which is fairly useful
in a small-scale cheese plant such as the subject in this study. Money is saved
by only spending on the critical control area of processing instead of the cost of
samples and the instruments to test the end products.
Recommendations
The HACCP plan in this study has not been implemented in the cheese
making process because of the limited resources and time. As a HACCP system,
the verification procedures which are the seventh principle must be included.
This principle can be effective by using an audit method to ensure the HACCP
plan is properly practiced in the production.
HACCP should become part of the culture of the plant. Improvement
should be continues.

44
To effectively implement a HACCP system, Supply Quality Assurance
and Good manufacturing Practice are essential supports. To ensure both the
validity and security of a HACCP system, Laboratory Accreditation and ISO
9000, and use of Statistical Process Control Techniques will be very useful.
HACCP is a universal system; it ensures the food safety for importing
and exporting food products.


















45
REFERENCE
1. Bardic, Allison. (2001). HACCP READY. Dairy Field 184 (2): 6.
2. Bennet, William L, Steed, Leonard L. (1999). An integrated approach to
food safety. Quality Progress 32 (2): 37-42.
3. Canadian Food Inspection Agency. (2001). Food Safety Enhancement
Program. Retrieved March 02, 2003, form
http://www.inspection.gc.ca/english/ppc/psps/haccp/haccpe.shtml
4. Dillon, M. and Griffith, C. (1995). How to HACCP. South Humberside, DN:
M.D. Associates.
5. FDA. (2001). NCIMS HACCP Pilot Program Phase II Expansion.
Retrieved February 20, 2003, from
http://www.cfsan.fda.gov/~comm/daipilo2.html
6. Fox, P.F., Guinee, T.P., Cogan, T.M., and McSweeney, P.L.H. (2000).
Fundamentals of Cheese Science. Gaithersburg, MD: Aspen Publishers.
7. Hill, R. (2000). Welcome to our cheese site. Retrieved October 10, 2002,
from http://www.foodsci.uoguelph.ca/cheese/welcom.htm
8. IFST. (1998). Food Safety and Cheese. Food science & technology today
12 (2): 117-122.
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