Good Milk Handling Standards

Implementation in Milk Collection

Centers and Good Manufacturing
Practices in Dairy Processing
Plants
KOSOVO CLUSTER AND BUSINESS SUPPORT PROJECT

August 2006
This publication was produced for review by the United States Agency for International
Development. It was prepared by the KCBS project team of Chemonics International Inc.
based on a Final Report prepared by Short Term Technical Advisor, Vladimir Kokarev.
Good Milk Handling Standards
Implementation in Milk Collection
Centers and Good Manufacturing
Practices in Dairy Processing
Plants

Kosovo Cluster and Business Support Project - Good Milk Handling Standards Implementation in Milk
Collection Centers and Good Manufacturing Practices in Dairy Processing Plants.
Contract No. AFP-I-00-03-00030-00, TO #800

This report submitted by Chemonics International Inc. / 12 September 2006

The author’s views expressed in this publication do not necessarily reflect the views of the United States
Agency for International Development or the United States Government.
CONTENTS

PURPOSE OF ASSIGNMENT............................................. 1

BACKGROUND ................................................................... 1

EXECUTIVE SUMMARY ..................................................... 2

FIELD ACTIVITIES TO ACHIEVE PURPOSES................... 3

TASK FINDINGS AND RECOMMENDATIONS................... 5

CONCLUSIONS AND RECOMMENDATIONS FOR

FUTURE ACTIVITY ............................................................. 7

ANNEXES ............................................................................ 8
PURPOSE OF ASSIGNMENT
The purpose of this assignment is to recommend the implementation of GMH standards in
one model Milk Collection Center (MCC) including providing written procedures for each step
of raw milk handling and testing. This MCC will serve as a model to other MCCs and be
used in trainings for their staff. The KCBS Project surveyed 10 MCCs using a standard
questionnaire to identify their strengths and weaknesses. On the basis of these
questionnaires the STTA and KCBS will select three MCCs for assessments and site visits
to determine which one to use as a model to implement/improve GMP.

BACKGROUND
Milk production is widespread throughout Kosovo and improvements in the production,
collection, processing and distribution of milk will lead to added income throughout the rural
sector.
The Kosovo dairy sector is poised to take a giant step forward with the increased production
of high quality milk. This production must be accompanied by the manufacturing and
marketing of high quality dairy products. The dairy sector is a prime example of how an
industry must progress in terms of basic procedures and systems and newer technology or
be left behind in the world market. A focused approach that brings new technology and
introduces good milk handling and manufacturing practices throughout the industry is critical
to raising Kosovo’s dairy industry to the next level of competitiveness.
The KCBS Project currently has nine commercial dairy processing companies as clients. In
total there are more than 25 dairy processing companies operating in Kosovo. Located
throughout Kosovo, these dairies have a total processing capacity of 85,000 liters of milk per
day. This processing capacity could easily be increased to 100,000 liters a day with minor
upgrades to existing equipment. The capacity ranges from 1,000 liters per day in the
smallest dairies, to 30,000 liters per day in the largest. They supply a very limited range of
dairy products to the domestic market. Presently, imported dairy products have a significant
share of the domestic market. In response to increased competition from imports, local dairy
processors are attempting to develop new products of their own. These new products
require higher quality raw milk and better milk handling, manufacturing, and distribution
practices.
Two systems are used for collecting raw milk. The first involves the dairy processor
collecting milk directly from the larger commercial farms. The second requires small farmers
to bring their milk to a central, privately operated Milk Collection Center (MCC). Dairy
processors Abi, Devolli, Ajka, Rona, Kabi, and Bylmeti are currently collecting milk from 55
MCCs with milk cooling tank capacities of 1000 lit/each. The dairy processors’ demands for
better quality milk are putting increased pressures on MCCs to supply higher quality milk.
Presently in Kosovo there is no MCC operating with Good Milk Handling (GMH) standards.
There is also a general lack of GMP (Good Manufacturing Practices) being standardized and
followed in the processing plants. This inconsistency throughout the dairy food chain results
in products of variable quality and inconsistent taste.

STTA Report –Vladimir Kokarev, August 2006 Page 1

EXECUTIVE SUMMARY
The Dairy Specialist joined additional consultants from KCBS to provide technical assistance
and training managers and staff of MCCs and dairy plants throughout Kosovo. The team
worked in Pristina, Peja and Prizren for a 12-day period during the month of August 2006.
A large number of MCCs and dairy plants are managed by young inexperienced workers or
by farmers with insufficient knowledge of GMP. This is the main factor leading to unsafe
products and limited shelf-life of products which directly correlates to the economic balance
of dairy plants. The main problems which lead to such conditions are: low product quality,
non standardization of products, unsafe products and low competition potential.
Target group of the project were MCCs that fulfilled the technical conditions for raw milk
receiving and dairy plants that have invested in implementation of GMP improvements of
facilities and other necessary equipment.
During the 12-day period, four MCCs and three dairy plants were visited. Almost all persons
who attended the meetings were directly involved in the management process. Managers
were educated on different topics for GMP management such as: good hygiene practice at
the dairy plants, management of MCCs, record keeping, cleaning procedures, and proper
working habits to minimize the possibility of cross contamination.
GMP was initiated at three dairy plants using the 1+2 model. This model indicates that one
dairy plant, Ajka, with the resources and capabilities required for implementation, will serve
as a model to two additional dairy plants, ABI and RONA. The main topic of the workshops
was Good Manufacture Practices with the following sub topics: milk receiving and cooling,
pasteurization process and temperature control, hygiene of workers and equipment, product
cooling and mastitis in dairy cows. All procedures that are important for production of
standard products were practically demonstrated. Critical points that effect the
microbiological quality of the products was pointed out starting with preparation of the starter
culture through to the sale of products.
GMP implementation was discussed at four MCCs with the goal to increase the hygienic
level at the collecting centers and to maintain the milk quality up to the moment of delivery to
the dairy plant. The following topics were included in the discussion: selection of proper
cleaning chemicals and equipment for cleaning the enterer, milk equipment and utensils;
procedure for cleaning the milk equipment; disinfection of the enterer, equipment and
utensils; proper sampling for microbiological and chemical analysis; application of blue
methylene test and evaluation of the results; training for handling with Lacto scan and pH
meter.
Due to the influence of microbiological quality of raw milk on the quality of dairy products and
their competitiveness on the market, the need to implement a payment system for raw milk
according to microbiological and chemical quality was discussed with the managers of four
dairy plants: AJKA-Prizren, Abi-Prizren, Goljaj and Rona. They were presented with the
European standards for raw milk quality for collection and transport and also the standards
for premises for intake and further processing the milk. The need for establishing at least
one independent laboratory in Kosovo for raw milk and dairy products testing was also
emphasized.

STTA Report –Vladimir Kokarev, August 2006 Page 2

FIELD ACTIVITIES TO ACHIEVE PURPOSES
In order to have a clear understanding of the current situation in various MCCs and dairy
plants, the consultant visited several facilities in Kosovo. The consultant also discussed the
current situation in the sector with the main stakeholders in order to educate them on the
importance of GMH and GMP implementation.

1st August 2006: KCBS Project Office

The consultant met with KCBS Project staff to plan the schedule of activities for the
assignment. The goal was to visit and select client(s) which in future will implement GMP
and start with recommendations for future activities which are necessary to implement Food
Safety Standards. Visiting plan included dairy plants and MCCs. During this time the
consultant also contacted BIOLAB to discuss services which they provided to dairy farmers
and MCCs.

2nd August 2006: Ajka Dairy Plant, Rugova and Kruseva MCCs
Met with Mr. Ramadan, owner of Ajka dairy plant, to discuss KCBS project activities related
to the implementation of Food Safety Standards and GMP. Mr. Ramadan agreed to start
with implementation of GMP standards which will be recommended by KCBS consultants
and asked the project to help them to improve quality of soft white cheese.
After the Ajka visit, the consultant visited two new milk collection centers in Rugova and
Kruseva to discuss possibilities for collaboration. Neither of the MCCs is operational at this
time, but both are working towards the final equipment installations and have agreed to
manager training before the commencement of milk collection.

3rd August 2006: Ajka Dairy Plant

A return visit was made to Ajka dairy plant to check all procedures for milk processing from
receiving to packing. Procedures were checked procedure for:
o Milk receiving - milk without cooling is transferred in a 1200L capacity lacto-freezer
o Storage - the same lacto-freezer used for cooling and storage.
o Processing - during pasteurization process it is difficult to control temperature.
o Packing -packing equipment for yogurt and set yogurt is automatic and for
pasteurized milk is semiautomatic.
o Storage - the cooling chamber satisfied needs for storage
o Soft white cheese - there are some mistakes being made which result in poor quality
of the final product.

4th August 2006: Ajka Dairy Plant and BIOLAB Consulting

During this visit the consultant developed a new procedure for soft white cheese, prepared a
starter culture for demonstrating cheese making procedures and inspected the plant. During
a meeting with the necessary changes were discussed on proper steps for GMP
implementation. The biggest investment will be a pasteurization unit together with
homogenization and separator. Also the receiving station has to be upgraded and a cool
water and hit exchanger installed.
The next meeting occurred with BIOLAB consulting to discuss future cooperation in GMP
implementation and share necessary information relevant for project.

5th August 2006: Ajka Dairy Plant

Working with 1200L of cow milk, the consultant made cheese to demonstrate the complete
procedures for cheese making - from milk receiving to cheese salting. All mistakes in
procedure for cheese making were discussed. Each day, the plant owners were introduced
to GMP requirements and improvements which have to be done in future.

STTA Report –Vladimir Kokarev, August 2006 Page 3

7th August 2006: ABI Dairy Plant
We met with the owner of ABI to discuss the current situation of plant and gain and
understanding of the privatization process which will be completed by the end of this year.
This company has a strong position in the market, understands the benefits of GMP and is
ready to implement standards.

8th August 2006: ABI Dairy Plant and Mamusa MCC

We organized a meeting with the general manager of ABI to explain the process of GMP
implementation and activities which will be done in future. He agreed to employ one more
person who will be responsible for the Quality Control Department and have a crucial role in
GMP implementations.
After meeting with ABI we visited the MCC in Mamusa. This MCC has moved to a new
location which is much better situated than the first one.

9th August 2006: Bec MCC and RONA Dairy Plant

We met with Musa Cerim, owner of the MCC in Bec. This MCC also has equipment for milk
pasteurization and cheese making. The equipment has never been used and they asked for
KCBS assistance and training in procedures for cheese-making.
We met with the general manager of RONA dairy plant. RONA plans to build a new facility in
2007 and anticipates KCBS assistance with this effort for equipment lay out.

10th August 2006: Goljaj Dairy Plant

This was the first visit to this dairy plant. Goljaj processes around 2000L of cow milk per day.
We discussed with the owner procedure for milk receiving, laboratory testing, processing.
The plant facilities and equipment satisfied GMP standards. This is the only dairy plant in
Kosovo which currently posts charts recording temperature of pasteurization and divert
valve. During the meeting future activities of KCBS project were explained.

11th August 2006: MCCs in Peja, Rausic and Istog

The Goljodjan-Peja MCC is in good shape and possesses all necessary equipment for milk
testing except test for inhibitors. The second MCC is located in Rausic and is owned by Mr.
Abedin Kastrati. The third MCC, in Istog, has a good operation and collects milk for two
dairy plants.

12th August 2006: Ajka Dairy Plant

A follow-up visit was conducted to check the cheese production process during fermentation
process and make further recommendations for GMP implementation.

14th August 2006: KCBS Project Office

The consultant met with the Kosovo Dairy Processors Association, Vet Animal Service, Vet
Public Health, and one of the managers of RONA dairy plant Rona to discuss Milk Quality
Systems.

STTA Report –Vladimir Kokarev, August 2006 Page 4

TASK FINDINGS AND RECOMMENDATIONS
At the selected dairy plants, managers and workers were trained on: transportation and milk
receiving, laboratory testing, milk cooling and storing, pasteurization process, recording and
controlling, cleaning procedures.
Activities at each model dairy plant proceeded in accordance with the following schedule:
1. Milk transportation: each dairy plant recorded the defects at milk collections process,
milk testing during collection (acidity and temperature), milk transport equipment, and
cleaning procedure.
2. Milk receiving and testing: During milk receiving process the consultant explained
procedures for milk reviewing and provided a list of necessary equipment for it.
Cooling the milk to a temperature below 8ºC limit the number of micro organisms and
maintains the microbiological quality. The dairy plants all have some of the necessary
equipment, but some of it is old or missing and must be replaced. If these plants want
to increase the quality of the final product, they have to reduce the length of the milk
cooling phase and invest in milk receiving equipment. The filtration process is also
one of the major problems because at the moment, the stainless steel filters that are
being used do not satisfy filtration needs.
Laboratory testing of raw milk is conducted during milk receiving. The dairy plants are
using standard techniques for milk testing, but the problem is that the test and
solution is not standard. The testing equipment needs to be calibrated and solution
for milk acidity testing is old. They also do not have written procedures for all
laboratory tests and schedules for calibrating equipment.
3. Milk pasteurization process: Proper milk pasteurization and recording processes
were demonstrated. Currently only one dairy plant posts the divert valve and
temperature chart recorder. The temperature recording and divert valve are Critical
Control Points and must be in place and checked daily before starting the
pasteurization process. Most of thermometers are not calibrated therefore making it
difficult to control pasteurization temperatures.
4. Cleaning procedure and pest control: The following proper operating procedures
were demonstrated using adequate tools and chemical solutions:
o Preparing area, equipment and personnel for cleaning
o Pre-cleaning - physical (dry)
o Pre-rinsing
o Chemical cleaning with acid or alkaline (chlorinated) detergents
o Inspection and re-cleaning, if necessary
o Sanitizing
Currently none of the dairy plants have plans for pest control. For GMP
implementation pest control conducted by professional companies is crucial. Dairy
plant managers must be educated on this.
5. Product storage and distribution: All of the dairy plants have cooling chambers for
final products. Temperature controls are visually checked by workers, but no
evidence of temperature probe calibration exists. Because the temperature of final
product is very important for shelf life and safety of product we recommended data
loggers for each cooling chamber. With 24-hour temperature recording information
the manager can locate problems which are connected with product cooling. The
same type of data loggers can be used for distribution tracks. At the end of each
week all record information can be analyzed and improvements made if necessary.

STTA Report –Vladimir Kokarev, August 2006 Page 5

Training was conducted at the Milk Collection Centers for permanent and temporary
employees. The goal was to increase the hygiene level at the collection centers and to
maintain the quality of the milk until distribution to the dairy plant. During the training,
demonstration was performed on:
1. Proper sampling and labeling the samples of the milk for chemical and
microbiological analysis, refrigerator storage at 0-4oC and transport of the samples
at a temperature of 0-4oC in sterile and well closed containers;
2. Control of the temperature during intake of the milk from the farmers;
3. Selection of proper cleaning chemicals for cleaning and disinfection of the premises,
equipment for storage the milk and other assisting utensils;
4. Introduction of procedures for cleaning and disinfection of the premises and
equipment at the collecting center;
5. Introducing methylene blue test as orientation control of the microbiological quality of
the milk: preparation of 0, 1% solution of methylene blue, testing of the milk,
evaluation of the results from testing and classification of the milk according the test;
6. Preparation of the alcohol test for determining the freshness of the milk: preparation
of 68-70% solution of ethyl alcohol, testing of the milk and proper evaluation of the
results form the test;
7. Usage of Lacto scan for determination of the chemical parameter of the milk, proper
evaluation of the results and procedure for cleaning the instrument;
8. Usage of pH meter: calibration of the instrument, testing the milk, evaluation of the
results and cleaning of the probe of the instrument;
9. Preparation of the titration method with the solution of NaOH for determining the
acidity of the milk: preparation of the solution NaOH, testing the milk and evaluation
of the results form the test.

STTA Report –Vladimir Kokarev, August 2006 Page 6

CONCLUSIONS AND RECOMMENDATIONS
FOR FUTURE ACTIVITY
Currently none of the processors in Kosovo have GMP implemented in their facilities. Food
safety is one of the top priorities for food processors and also one of the factors for
consumer confidence and due diligence. Other countries in the region have already initiated
implementation of these standards and in some countries all of the processors are certified
in food safety standard implementation. This fact makes processors in Kosovo uncompetitive
when compared to neighboring countries. For now, local consumers have higher confidence
in imported products.
For these reasons it is essential that the processors in Kosovo start and continue with
implementation of food safety standards as soon as possible. The implementation of these
standards is critical not only for domestic but for export market as well. Certification on food
safety standards will increase product assurance and facilitate the export of dairy products to
EU countries.
Recommendations are as follows:
1. GMP implementation to be carried in the selected dairy plants. This means that the
client of KCBS - Dairy Plant ABI that has required resources and capability can be
the best for implementation and the other two (Goljaj and Ajka Diary Plants) will
follow its example.
2. Currently it is not possible to assess which processors have the determination to start
with implementation of food safety standards and it will require additional monitoring
time to decide which client will have results in the implementation process first.
3. The same recommendation refers to MCCs, which means that two milk collecting
centers will serve as example to other two.
4. It is necessary for the dairy plants and milk collecting centers to recognize the need
for laboratories to perform chemical and microbiological tests for their products.
5. In order to fulfill the above mention recommendation it is necessary that the future
training is provided to the Veterinary inspectors, dairy companies and KCBS Project
employees.

STTA Report –Vladimir Kokarev, August 2006 Page 7

ANNEXES
Annex I Detailed Equipment List for Milk Collection Centers

Annex II Detailed Equipment List for Dairy Plants

STTA Report –Vladimir Kokarev, August 2006 Page 8

ANNEX I: DETAILED EQUIPMENT LIST FOR
MILK COLLECTION CENTERS

Facility: Ensure that the buildings are of adequate size and are designed and built to
facilitate maintenance, cleaning and sanitary operations, prevent entry of insects and other
animals, facilitate waste treatment and disposal, and prevent mix-ups and cross-
contamination.

Equipment
o Milk receiving pump with filter
o Plate heat exchange with ice water generator or lactofrizers
o Food grade tube for milk receiving and manipulation
o Temperatures display and data recording
o Hot water -boiler

Laboratory
o Thermometers
o Alcohol probe
o Containers for tacking samples
o Mastitis probe
o Antibiotic and Inhibitor tests
o PH meter
o Refrigeration unit for milk samples storage

Cleaning solutions
o Acid solution
o Alkal
o Disinfection

Pest control
o traps for mouse, flay killer units

Documentation
o Written procedure for all laboratory procedure
o Pest control plan
o List of farmers and records
o Written procedure for coding system
o Written procedure for milk receiving, storage
o Records for training
o Standards for milk
o List of equipment
o Plan for calibration
o Cleaning procedure and records

Maintains
o Plan for maintains
o Records for maintains
o Contract wit external company

STTA Report – Vladimir Kokarev, August 2006

ANNEX: II DETAILED EQUIPMENT LIST FOR
DAIRY PLANTS
Every natural health product shall be manufactured, packaged, labeled and stored using
equipment that is designed, constructed, maintained, operated and arranged in a manner
that
a) permits the effective cleaning of its surfaces;
b) permits it to function in accordance with its intended use;
c) prevents it from contaminating the natural health product; and
d) prevents it from adding an extraneous substance to the natural health product.

To meet the requirements manufacturers, packagers, labelers, importers and distributors

must do the following.
1. Ensure that production equipment is designed, constructed, installed and maintained
to facilitate cleaning, sanitizing (where appropriate), and inspection of the equipment
and the surrounding areas. Specifically, this means the following:
a. establishing and following procedures for cleaning and maintaining equipment
and utensils used to manufacture products;
b. avoiding temporary repairs (e.g. with tape); and
c. clearly labeling defective equipment as such.
2. Ensure that production equipment and utensils having direct contact with materials
and products are constructed of smooth, non-reactive and non-toxic materials, and
are designed to withstand repeated cleaning.
3. Minimize the possibility of lubricant or other maintenance materials contaminating the
products by ensuring proper equipment design (e.g. tanks, chain drives and
transmission gears must be enclosed or properly covered).
4. Control and monitor temperature-sensitive compartments, and keep records of this
work.
5. Properly maintain instruments and controls, including laboratory equipment, to
ensure that they remain accurate, and retain records of this work.
6. Develop a calibration program for critical manufacturing, packaging and testing
equipment, and maintain records of this work.
7. Maintain records of equipment and facility cleaning.
8. Maintain equipment usage logs.

LIST OF EQUIPMENT:

Milk transportation
o Isolated inox tank for milk transportation
o Field equipment for milk measurement and acidity testing -alcohol probe or Ph meter
o Milk transfer pump
o Equipment for milk measurement

Laboratory
o Acidity testing equipment -Ph meter and titrated
o Inhibitors and antibiotics testing equipment
o Thermometers
o Refrigeration unit for milk samples storage
o Containers for tacking milk samples

Milk receiving and storage

o Milk pump with filter

STTA Report – Vladimir Kokarev, August 2006

 o Plate heat exchanger
o Ice water
o Isolated milk storage tanks

Milk pasteurization unit

o Temperature control
o Continue temperature chart recorder
o Divert valve
o Holding tube
o Homogenization
o Separator

Yogurt fermentation tanks

o Temperature probe
o Isolation

Pasteurized milk tank

o Isolation

Packing line for: Yogurt, set yogurt and pasteurized milk

Cooling chambers
o Isolated and easy clean
o Data logger for temperatures recording
Track for distribution
o Isolated
o Temperature control
o Data logger for temperature control
CIP system for cleaning -Transport tanks and separate for dairy plant
o Acid
O Caustic

STTA Report – Vladimir Kokarev, August 2006