HACCP Plan for Ice Cream

production

Prepared by:-
Rajan Sigdel
RA1812036010016
M.Tech.FSQM
2nd sem
FSR2005
 Introduction
 To guarantee the safety of ice cream
production, the Hazard Analysis Critical
Control Points (HACCP) system was
applied to the production process. The
biological, chemical, and physical hazards
that may exist in every step of ice cream
production were identified.
 Implementing the HACCP system in food
manufacturing can effectively ensure
food safety and quality, expand the
market, and improve the manufacturers’
management level.

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 Background on HACCP
 HACCP is a world-recognized, effective, and
preventive food hygiene management
system.
 In consideration of the booming
development of the catering industry and
the increasing number of food poisoning
incidents, the development of HACCP
practices stage by staged mandatory for
implementation.
Implementing HACCP is helpful for
 gaining consumers’ trust
 establishing a good corporate image
 Break down trade barriers and participate
in international business,
 expanding their markets and increasing
profits
 improve their management level and
enhance their staff’s safety consciousness.
 Ice cream is a good microbial growth
medium because of its nutrients
(lactose, protein, carbohydrate, etc.)
and neutral pH profile
 Therefore, preventing microbial
contamination has been crucial for its
safety control. HACCP has been proven
to be effective in inhibiting the growth
of Staphylococcus aureus, Escherichia
coli, and other human pathogens in ice
cream production

 Before HACCP can be introduced for a

process, some prerequisites have to be
in place.

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 Principles of HACCP
 Hazard analysis is a key part of the HACCP
study. When performing a hazard analysis,
agents posing a possible health threat are
identified. The different hazards are then
evaluated to assess the severity and risk.
Only significant hazards will be addressed,
and preventative measures have to be
found for these hazards.
 Identifying of critical control points: A
critical control point (CCP) is a step in the
production process, in which a hazard can
be controlled. Each hazard must be
controlled in a CCP, which for instance could
be a pasteurization step.
 Critical limits are then set for the CCP. If a
limit is not met, for example a temperature
limit, the process is not sufficient to
produce a safe product.
 Procedures for monitoring the critical
limits are then implemented. When the
critical limit is a temperature, the
monitoring could be performed with a
continuously measuring thermometer.
 Corrective actions are to be taken if the
monitoring system reports that a critical
limit is not met. Actions must be defined
for each CCP in the HACCP plan.
 Verification procedures are used for
evaluating the process, to make sure that
everything complies with the HACCP plan.
 Documentation must be kept for all work
regarding HACCP
 Ice cream history
 The history of ice cream is described
differently depending on source.The first
ice cream was probably sorbet made in
China, 5000 years ago.
 Ice cream making, as well as the
technique to keep it cold with ice and
salt, spread through Asia and found its
way to Europe.
 In Italy, the sorbet was further
developed and also was the place for
inventing “real” ice cream, i.e. made
from cream. In the 17th century Louis XIV
of France had ice cream as his favourite
dessert and his chef was the first to
make vanilla and chocolate ice cream.
Flow Diagram for Ice cream Production
Raw material

Mixing

Homogenization
(130 bar, 70°C)

Pasteurization
(83°C)

Aging (4°C)

Freezing

Packaging

Hardening (-32°C)

Storage/Transport
(-18°C)
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 Production process
 The process for making ice cream
production include mixing of the
ingredients, homogenization, pasteurization,
aging, freezing, packaging and hardening.
 All the ingredients are mixed in the
beginning of the process. Then the mixture
is heated to 60°C before homogenization at
70°C and 130 bar. Pasteurization is
performed at 83°C for about 20 seconds,
and then the ice cream mix is chilled to 4°C.
The aging step at this temperature lasts for
12–24 hours. Then the ice cream mix is
frozen to -5°C. At -5°C the ice cream is still
soft, so it can be filled into plastic packs.
The ice cream is quickly hardened in a
tunnel at -32°C. The finished product is
stored at least at -18°C.
 Hazard analysis
 The National Food Administration (2006)
mentions Bacillus cereus, Listeria
monocytogenes and allergens as examples
of hazards with ice cream.
 There are a number of incidents that could
be hazardous when it comes to food
safety. Insects, birds and other organisms
may find their way into the production
facility. These may contaminate the ice
cream and spread disease. Though, this
can be subjected in the routines included
in GHP.
 When considering whether or not to
address the problem of a hazard in the
HACCP plan, one has to consider how
serious the hazard is and how often the
hazard occurs.

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 Bacillus cereus
 Due to the ability to form spores and the
fact that it is present almost everywhere,
B. cereus is difficult to get hold of in the
food industry. In milk products, like ice
cream, the organism may enter for
example through contamination at the
milking.
 At pasteurization temperature vegetative
cells die. However, spores may survive
and germinate when the temperature is
lowered. Since gram-positives generally
have a higher tolerance to freezing
 B. cereus can be suspected to be of
concern in ice cream.
 Listeria monocytogenes
 The contamination of the milk could
originate from dirty udders. In the
worldwide perspective, L.
monocytogenes in ice cream products is
of significant food safety concern.
 Since L. monocytogenes may result in
health hazard among the susceptible
groups and it may enter the milk at
milking, it must be addressed as a hazard
in the HACCP plan, and may be controlled
by pasteurization.
 Salmonella
 The ice cream does not contain egg, but
milk, cream and whey powder are all of
animal origin. Luckily the organism’s heat
sensitivity makes it possible to eliminate
with pasteurization.
 The severity of the disease in combination
with the risk makes Salmonella a hazard to
target in the HACCP plan.

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 Mycotoxins
 When a cow eats a feed contaminated
with aflatoxin B1, the activity of the
cow changes the aflatoxin B1 to
aflatoxin M1, which ends up in the
milk. This leads to a concern for
contamination of aflatoxin M1 in ice
cream.
 There is no tolerable daily intake (TDI)
for aflatoxins, which are to be kept at a
level as low as possible. Though,
maximum levels are set in the
European Union, for example 0.05
µg/kg of milk for aflatoxin M1.
 Since aflatoxins have a cumulative
negative effect in humans they should
be considered as hazards in the HACCP
plan.
 Allergens
 The ice cream contains ingredients that
some people are allergic to. These
allergens are milk (and cream), almond
and soy lecithin. When such ingredients
are used the product must be labelled.
 There is a risk for contamination of trace
amounts of these allergens, and this must
be avoided. Good routines for handling
the allergens and for cleaning the
equipment are needed. Such routines are
not something to be taken up in the
HACCP plan, but are instead necessary to
treat within the GHP.
.

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 Summary

Step Potential Justification To be Control

hazard addres measure
sed?
Addition of milk Bacillus Known to Yes Pasteurization,
and cereus occur Chilling
cream

Addition of milk Listeria Known to Yes Pasteurization

and monocytoge occur
cream nes

Addition of milk, Salmonella Known to Yes Pasteurization

cream and whey occur
powder

Addition of milk, Aflatoxin Known to Yes Analysis by

cream occur Manufacturer
and almond

Addition of milk, Ingredients Some people Yes Labelling

cream, are are
almond and soy allergenic Allergic
lecithin

Whole process Contaminati Some people No GHP

on with are
nuts and Allergic
eggs
 Critical control points
 Every hazard found to be significant
enough to be addressed in the HACCP
plan has to be controlled in a CCP – a step
essential to prevent that hazard.
 In this section the whole process is gone
through to establish whether or not each
step may be considered to be a CCP. Also,
the critical limits, monitoring procedures
and corrective actions are settled.

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 Raw materials
 When raw materials arrive at the factory
it is important that they have a good
quality.
 The hazard, for which the raw material
delivery is a CCP, is aflatoxin.
 The supplier should ensure good quality
of almonds
 Documents have to be enclosed with each
delivery
 In this case the critical limit is that such
documents exist.
 The monitoring procedure for this CCP is
to control that the proper documents
exist at each delivery.
 The corrective action to apply if the
documents are absent is to send the
material back to the supplier, and change
supplier if the problem recurs.
 Pasteurization
 Pasteurization affects most of the
hazards mentioned earlier. Vegetative
cells of the different pathogens die
when properly pasteurized.
 After this step there will be no more
step able to efficiently reduce the
amount of organisms, and therefore it
will be crucial for quality.
 Pasteurization will be a CCP, for which
critical limits now will be established.
 Aging
 Rapid chilling of the ice cream mixture
and keeping it at the correct temperature
during the aging step is important, so
microorganisms are unable to grow.
 B. cereus, the heat resistant spores may
also be grown due to inefficient cleaning
and disinfection.
 The temperature will be a way to prevent
the microbial hazard. The critical limit will
be set at 5°C (HKSAR Government, 2001).
Though, the process is normally ran at
4°C.
 The limit will be monitored using a
continuous thermometer.
 packaging
 Hygiene in these steps is crucial for the
product, since no elimination of
pathogens is done later. Though, this is
something for GHP to target.
 Labelling concerning the allergenic
ingredients in the product is a CCP.
 The critical limit is that the correct
packaging is used. This has to be visually
monitored by personnel as the packs are
put into the packing machine.
 Hardening, storage and transportation
 The hardening step in the ice cream
production is not critical for microbial
hazards. The ice cream is already cold
enough for halting microbial growth
sufficiently.
 The step will there- fore not be part of
the HACCP plan. It is only for other quality
reasons that the parameters in the
hardening step are important.
 The same applies on the storage and
transportation steps, which should have a
temperature of -18°C.

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 Verification and documentation
 A number of routines for evaluating and
keeping record, of that the work is carried
on according to the HACCP plan, has to be
implemented.
 Verification includes a validation of the
HACCP plan before it is used and once a
year for it to still be accurate
 All records of delivery control, temperature
data and packaging checks must be kept
properly. The whole work regarding the
HACCP plan – including background data,
verification, and information on who is
responsible for what – has to be
documented as evidence for the system to
work properly.
 Summary

CCP Hazards Critic Monitori Corrective Records Verifi-

al ng actions cation
limit
s

Review
Milk, Aflatoxin No Suppli Return Deliv of
cream toxin er delivery, ery suppl
and guaran change check ier,
almond tee supplier s revie
w
recor
ds

Bacillus 83°C Thermom Tempera Revi

Pasteurizati cereus, for eter and Repasteuriz ture, ew
on Listeria three flow ation time recor
monocytogen meter (flow) ds
es seco
and nds
Salmonella

Aging Recontamina 5°C Thermomet Discarding Tempera Review

tion er or ture records
Repasteuriz
ation

Labelling Allergens Corre Visual Discarding Packagin Review

ct control g records
pack checks

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 References
 Adams, M.R, Moss, M.O. (2000). Food
Microbiology. Second edition. The Royal
Society of Chemistry.
 Börzsei, Carolina (2005). En Handbok Glass.
First edition. Grenadine Bokförlag AB.
 Eckner, KF. (1992). Fluorometric analysis of
alkaline phosphatase inacti- vation
correlated to Salmonella and Listeria
inactivation. Journal of Food Protection. Vol.
55, no. 12, p. 960–963.

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Thank you