PennStateBerkeyCreameryJuiceHACCP 2010

Berkey Creamery

JuiceHACCPPlan EditedMay,2010. By: BenjaminThomas

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PennStateBerkeyCreameryJuiceHACCP 2010

TableofContents:
HACCPTeamandProductStatementwithProcessFlowDiagram HACCPVerificationSheet HazardAnalysisSummaryTable HACCPPlanSummaryTable SOP002.002(OrangeJuiceProduction) 8SSOPs
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pg.3 pg.4 pg.5 pg.6 pg.7 pg.9

PennStateBerkeyCreameryJuiceHACCP 2010
HACCPTeamforthePennStateBerkeyCreamery: Dr.LukeLaBorde Ms.BonnieFord Mr.JerryWinn Mr.ThomasPalchak Mr.WilliamKurtz Mr.JamesBrown Ms.SusanWatson

BERKEY CREAMERY PRODUCTION AND DISTRIBUTION FLOW DIAGRAM Product: Ingredients: Processing: LabelingandUseInstruction: ConfirmatoryTest: Packaging: TransportationandDistribution: IntendedConsumers: ShelfLife
Orange Juice Concentrate

100%PureFloridaOrangeJuicefromConcentrate Water,orangejuiceconcentrate Allingredientsarepasteurized Codedwithsellbydate,andkeeprefrigerated Noproteinpresentinproduct 1gal,1/2gal,qt,andpintHDPEplasticbottleswith tamperevidentseals. Storedanddistributedunder40F UniversitydininghallsandCreamerystore 45daysfromcodedating

Received and stored under (-20F)

University Water Supply

Drums thawed and stored under 40F

Mixing (balance tank of HTST)

Water Softener

1 gal bottles

Pasteurization (CPP#1)

gal bottles

Pasteurized Storage at or below 40F

Verification of Brix (11.8-12.2%)

Quart bottles

Packaging

Pint bottles

Confirmatory Test for Protein

Storage and Distribution (under 40F)

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PennStateBerkeyCreameryJuiceHACCP 2010
BERKEY CREAMERY HACCP SYSTEM VERIFICATION SHEET

EvaluationofProductandProcess

YES

No

IfYes,describe

FoodSafety Implications

Aremodificationsof theHACCPplanof HazardAnalysis required?

Productdescriptionchange? Formulationchange? Ingredientchange? Packagingchange? Newconsumptionorstoragemethods? Newsuppliers? ProcessChange? Addedorchangedequipment? Finishedproductdescriptionchange? ExcessiveCCPdeviations? Anyproductrecall? Anyneworemerginghazards? Anyfoodsafetyconsumercomplaints? DotheCCPscontrolthehazard? AretheCCPcriticallimitsadequate? Domonitoringmethodsandtheir frequencyadequatelyidentify deviations? Arerecordkeepingprocedures adequate? Doverificationactivitiesincludethe calibrationofprocessmonitoring instruments? Doesverificationincludereviewof consumercomplaints? Doesverificationincludethereviewof records? Aretheprerequisiteprogramsand/or SSOPsidentifiedinthehazardanalysis asreducingthelikelihoodofhazards stilleffective?

EvaluationofProductSafetyHistory

EvaluationofCCPs,Criticallimits,Monitoring,Correctiveactions,CCPVerification,Recordkeeping

Verificationconductedby:__________________________________________ SignatureofLaboratoryDirector:_____________________________________

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PennStateBerkeyCreameryJuiceHACCP 2010

BerkeyCreameryHazardAnalysisSummaryTable Product:100%PureFloridaOrangeJuicefromConcentrate
Process,Step,IngredientorInput IdentifythePotentialHazard (B)iological (C)hemical (P)hysical Isthehazardsevereand ofsufficientlikelihoodto warrantitscontrol? Isacontrolmeasureavailableatthishazard correctlyapplied,monitored,anddocumented inaPrerequisiteProgram(PP)orother procedure? Ifnot,couldandexistingPPbemodifiedora newPPestablishedtocontrolthehazard. Ifso,identifythePPanditslocation Ifyes,stopanddocument Ifno,proceedtonextquestion No Yes:CertificateofAnalysis;Productseals Yes:CertificateofAnalysis;ProductSeals Doesacontrolmeasureexistat thissteptoprevent,reduceor eliminatethelikelyoccurrence ofahazardtoanacceptable level? Ifyes,documentasaCCP IfNo,indicatewherethiswill happen No:Pasteurization

OrangeJuiceConcentrateReceiving

ConcentrateStorage

Ingredients:Water

Pasteurization

Packaging

ProductStorage

B C P B C P B C P B C P B C P B C P

Yes Yes Yes No No No Yes Yes Yes Yes No No Yes No No Yes No No

No Yes:Mustbepotable;commerciallabcertification No No

No:Pasteurization

Yes:CCP#1

Yes:LetterofGuarantee Yes:LetterofGuarantee Yes:LetterofGuarantee Yes:SSOPsandGMPtraining

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PennStateBerkeyCreameryJuiceHACCP 2010

BerkeyCreameryHazardAnalysisSummaryTable Product:100%PureFloridaOrangeJuicefromConcentrate
CriticalControl Point CPP#1 Pasteurization (HTSTwithouta magneticflow metersystem) Hazards Biological Vegetative Pathogens(non sporeformers) CriticalLimits What Temperature Time Pressure Monitoring How Safety thermallimit recorderand chartrecorder Timingpump Pressure differential controller Frequency Continuous Who Pasteurizer operators CorrectiveActions Verification Records

Temperatureas measuredatthe exitoftheholding tubemustexceed 161F HoldingTimemust begreaterthan15 seconds Pressure differential between pasteurizedand rawproductmust begreaterthan 1p.s.i

Automaticdiversion ofproductflow Isolationofaffected product Evaluateand determinethe dispositionofthe product Documentallactions

Cutin,cutout performed Indicatingvs. recording thermometer compared Pressure differential checks Equipment calibration Sealchecks

Pasteurization charts Equipment calibration records Corrective actionrecords

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PennStateBerkeyCreameryJuiceHACCP 2010

SOP:002.002 EffectiveDate:11/29/06 SupersedesSOP:002.001EffectiveDate:08/25/04

STANDARDOPERATINGPROCEDUREOrangeJuiceProduction

INTRODUCTION
Orangejuiceispreparedfromaconcentrate,pasteurized,andthenpackagedforwholesaleandretail distribution.

MATERIALS
1. Supplies a. Sanitizer b. Swabsthatdetectmilkprotein c. Orangejuiceconcentrate d. Brixrefractometer e. Chartpaper f. Recordofmanufactureform Hazards a. Burnsfromhotwaterandhotmetal. b. Corrosivedamagetoeyesandskinfromsanitizer.Weargogglesandgloveswhenusingthe concentrate.Avoidbreathingthevapors.

2.

PROCEDURE
1. Preproductionsanitation a. Discardthesanitizingsolutionthatwasheldinthefillerbowls,allowingittoflowthroughthe fillertubesandontothefloor. b. Prepareatleast300gallonsofsanitizingsolutioninamixingtank.Testtheconcentrationand recordtheresultonthesanitationtestrecord. c. PumpthesanitizingsolutionthroughthelinesleadingtotheHTST,throughtheHTST,andthen tothetankthatwillbeusedfororangejuiceproduction.Finally,pumpthesanitizingsolution fromtheorangejuiceproductiontankthroughthelinestothefillers,allowingittooverflowthe bowlsandtoflowthroughallofthefillertubesandthenontothefloor. d. StarttheHTSTandpasteurizesomewater.Runthiswaterthroughthelinesleadingtothetank thatwillbeusedfororangejuiceproduction,thenthroughthelinestothefillers.Allowthe pasteurizedwatertooverflowthebowlsandtoflowthroughallofthefillertubesandthenonto thefloor. e. Swabfoodcontactsurfaces.Ifresultsindicatethepresenceofmilkproteinresiduesrepeatthe sanitationprocedure.

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2. Production 1. Allowthefrozenorangejuiceconcentratetothawat<40F. 2. Preparechartsandstartthemrecordingthepasteurizingconditionsandthetemperatureofthe pasteurizedstoragetank. 3. Pumpsomesoftwaterintothemixingtank. 4. Addtheorangejuiceconcentrateandmixwithhighagitation. 5. PumptheorangejuicethroughtheHTSTataminimumof161Fandaholdingtimeofatleast15 seconds.Thepasteurizedjuiceshouldbedirectedintothepresanitizedpasteurizedstorage tank. 6. Pasteurizetheremainingvolumeofsoftwaterandaddthistothepasteurizedstoragetank. 7. Withcoolingandhighagitationturnedon,mixforatleast30minutes. 8. TastethejuiceandchecktheBrix.TheBrixreadingshouldbebetween11.8and12.2 9. Swabfoodcontactsurfaceatfillernozzleforpresenceofmilkprotein. 10. Fillcontainersandstorethemat<40F.

RECORDKEEPING
1. 2. 3. 4. Eachdaythatorangejuiceispreparedarecordofmanufactureformshouldbefilledout.Thiswillspecify theingredientsused,thevolumeofjuicemade,andtheresultsofthemilkproteinresiduetest. Chartsshouldbeusedtorecordthepasteurizationconditionsaswellthetemperatureofthepasteurized storagetank. Recordtheresultsfromthesanitizerconcentrationassaysontheweeklysanitationtestform. Retainallrecordsforatleasttwoyears.

REFERENCES
1. 2. ThefollowingindividualisresponsibleforimplementationofthisSOPandhastheoverallauthorityonsite: Name:____________________________Title:__________________________Date:_______________ PennStateBerkeyCreameryJuiceHACCPPlan(mostrecentversion). SOP005ChartUsage

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PennStateBerkeyCreameryJuiceHACCP 2010

SSOP:001.002 EffectiveDate:11/22/06 SupersedesSSOP:001.001 EffectiveDate:10/22/04

SANITATIONSTANDARDOPERATINGPROCEDUREWater,Steam,andIceSafety

INTRODUCTION
Wateriscriticalforfoodproductionandplantsanitation.Potablewater,coolingwater,steamandice mustbesafeanditmustbeavailableinsufficientquantities,atsuitablepressuresandtemperatures,tomeet operationalrequirements. TheBerkeyCreameryusestreatedwaterfromwellfieldsownedandmaintainedbyThePennsylvania StateUniversity.ThesewellsprovidewaterfortheUniversityParkCampusofPennStateandarethestate approvedsourceofallwaterneeds,includingthecleaningandrinsingofequipment.

FACILITIES
1. Potablewatersupply: a. Thepotablewatersupply,includingthesoftwatersystem,ismaintainedbythePennsylvania StateUniversitiesOfficeofPhysicalPlant.Allwaterenteringthebuilding,includingthewater thatisusedasaningredientorthatgoestotherefrigerationsystem,passesthrougha chlorinationprocess. b. BacteriologicaltestingofthepotablewaterisconductedmonthlybyPennStateand semiannuallybyanapprovedcommerciallaboratory. c. Waterpipes,hoses,andotherconnectionsthatcouldpossiblyresultincontaminationofthe potablewatersupplymustbeequippedwithproperlydesignedphysicalbreaks,antisiphonor antibackflowdevices. d. Crossconnectionsbetweenpotableandnonpotablewatersupplysystemsmustnotexist. Coolingwatersupply: a. Thecoolingwatersupplyismaintainedandtestedmonthlybyacommercialwatertreatment company. b. Watertreatmentchemicalsmaybeaddedaccordingtothemanufacturersdirectionswhen needed. c. Bacteriologicaltestingofthecoolingwaterisconductedsemiannuallybyanapproved commerciallaboratory. Steamsupply: a. ThesteamsupplyismaintainedbythePennsylvaniaStateUniversityOfficeofPhysicalPlant. b. Unfilteredsteamdoesnotcomeintodirectcontactwithfoodorfoodcontactsurfaces. c. Filteredsteamoriginatesfrompotablewater. d. Culinarysteamiscarbonfiltered.Thefilteristobechangedeverysixmonths,andverification recordskept. Icesupply: a. IcemakingmachinesaremaintainedbythePennsylvaniaStateUniversityOfficeofPhysicalPlant. b. Alliceismadefrompotablewater. c. Iceishandledandstoredinamannerthatprotectsitfromcontamination. Reclaimedwatersupply:

2.

3.

4.

5.

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PennStateBerkeyCreameryJuiceHACCP 2010

6. a. TheCreamerydoesnotusereclaimedwater. Distilledwatersupply: a. ThedistilledwatersupplyismaintainedbythePennsylvaniaStateUniversityOfficeofPhysical Plant.

RECORDKEEPING
1. 2. 3. TheUniversitymaintainsdocumentationonthewatertestsconductedforchemical,microbiological, turbidityandradiologicalparameters. MicrobiologicaltestresultsofthewatersupplythatareconductedbyPennStatearemaintainedinthe OfficeofPhysicalPlant. AllotherresultsfromtheanalysisofthepotableandcoolingwatersuppliesaremaintainedattheBerkey Creameryforatleasttwoyears.

ThefollowingindividualisresponsibleforimplementationofthisSSOPandhastheoverallauthorityonsite:

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PennStateBerkeyCreameryJuiceHACCP 2010

Name:____________________________Title:__________________________Date:_______________

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PennStateBerkeyCreameryJuiceHACCP 2010

SSOP:002.001 EffectiveDate:01/12/07

SANITATIONSTANDARDOPERATINGPROCEDUREProcessingEquipmentCleaningand Sanitation

INTRODUCTION
Cleanandsanitizedprocessingequipmentandutensilsareessentialtothemanufactureofsafefood products.Processingequipmentiscleanedaftereachdaysrunandsanitizedimmediatelypriortothenext use.Mostequipmentinadairyplantiscleanedinplace(CIP)usingacomputercontrolledmultistepsystem. ItemsthatcannotbecleanedwiththeCIPsystemmustbecleanedandsanitizedaftereachusebyhandorina COP(cleanedoutofplace)tub.

MATERIALS
1. Supplies a. Cleaningandsanitizingagents b. Cleaningequipmentsuchasgloves,brushes,buckets,andfoamsprayers c. COPtub d. Sanitationtestrecords Hazards a. Burnsfromhotwaterandhotmetalparts b. Chemicalburnstotheskinandeyesfromexposuretocleanersandsanitizers.Wearglovesand goggleswhenusingtheconcentratedchemicals.Avoidbreathingthevapors.

2.

HANDCLEANINGPROCEDURE
1. 2. UtensilsanditemsthatcannotbeadequatelycleanedwiththeCIPsystemmustbehandwashed. Theseitemsaredismantledandprerinsedwithwatertoremovetheheavysoil,thenhandscrubbed usingachlorinatedalkalinedetergent,andrinsedagainwithwater.Wirescreensmustbeautoclaved followinghandwashing. ThecleaneditemsarereassembledandsanitizedpriortouseusingtheCIPsanitizingcircuitifpossibleor dippedinasanitizingsolution.

3.

CLEANEDOUTOFPLACEPROCEDURE
1. 2. 3. 4. 5. 6. 7. 8. Dismantleequipmenttobecleanedandrinsewithwater. PlacethepartsinaCOPtubandfillthetubwithapproximately150to200gallonsofwater. Turnthecirculationpumponandheatthewaterto170F. Slowlyaddthenecessaryamountofchlorinatedalkalinecleaner. Collectasampleofthecleaningsolutionandtestthealkalinityandchlorineconcentrations. Circulatehotwaterandcleanerforatleast30minutes. AllowtheCOPtubtoemptyintoafloordrain. Rinsetheequipmentwithanapprovedsanitizer.

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PennStateBerkeyCreameryJuiceHACCP 2010

9. Visuallyinspecteachpieceofequipmentforpossibledamageandthepresenceofresidualcleaner. 10. Reassembletheequipmentandreturnittoitsstoragearea.

OPERATIONOFTHERAWCIPCIRCUIT
1. TherawCIPcircuitisusedtocleanthemilkdeliverytruck,therawmilksilo,therawmilkreceivinglines andpumpaswellastherawlinesleadingtotheprocessingplant.Additionally,thetwomixingtanksand theBreddoLiqwifierarecleanedandsanitizedusingtherawCIPcircuit. Ifneeded,theequipmentisprerinsedwithwatertoremovemostoftheresidualproduct. ThenecessarylineconnectionsaremadeandtherawCIPprogramisactivated. a. Thefirststepisawaterrinse b. Thenwaterisheatedandachlorinatedalkalinedetergentisadded.Thissolutioniscirculated throughoutthecircuitwhilevalvesandagitatorsareperiodicallypulsedtoaidinsoilremoval. c. Thewashcycleisfollowedbyawaterrinsewhichcoolsdownthecircuit. d. Finallyanacidsanitizerisadded,circulatedthroughoutthecircuit,andallowedtodraintothe floor. e. Thelineconnectionsarereturnedtotheiroriginalconfiguration. PriortotheequipmentsnextuseaCIPsanitationstepisperformedusinganacidsanitizer.

2. 3.

4.

OPERATIONOFTHEPASTEURIZEDCIPCRICUIT
1. 2. 3. ThepasteurizedCIPcircuitisusedtocleantheallofthepasteurizedstoragetanks,fillerlines,andthe bottleandbagfillingequipment. Ifneeded,theequipmentisprerinsedwithwatertoremovemostoftheresidualproduct. ThenecessarylineconnectionsaremadeandthepasteurizedCIPprogramisactivated. a. Thefirststepisawaterrinse b. Thenwaterisheatedandachlorinatedalkalinedetergentisadded.Thissolutioniscirculated throughoutthecircuitwhilevalvesandagitatorsareperiodicallypulsedtoaidinsoilremoval. c. Thewashcycleisfollowedbyawaterrinsewhichcoolsdownthecircuit. d. Finallyanacidsanitizerisadded,circulatedthroughoutthecircuit,andallowedtodraintothe floor. e. Thelineconnectionsarereturnedtotheiroriginalconfiguration. PriortotheequipmentsnextuseaCIPsanitationstepisperformedusinganacidsanitizer.

4.

OPERATIONOFTHEHTSTCIPCIRCUIT
1. TheHTSTCIPcircuitisusedtocleanthebowl,homogenizer,separator,andpasteurizer,allofthelines connectingthesepiecestoequipment,aswellasthelinesandvalvesleadingtothepasteurizedstorage tanks. Ifneeded,theequipmentisprerinsedwithwaterandthebowlisallowedtooverflowwithwaterinorder toremovemostoftheresidualproduct. ThenecessarylineconnectionsaremadeandtheHTSTCIPprogramisactivatedfollowingtherequired initialtenminutedelay. a. Thefirststepisacausticrinseusinganalkalinecleaner.Thissolutioniscirculatedthroughout thecircuitwhilevalvesareperiodicallypulsedtoaidinsoilremoval.Itisalsoallowedto overflowthebowl. b. Thecausticrinsecycleisfollowedbyawaterrinse.

2. 3.

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PennStateBerkeyCreameryJuiceHACCP 2010

Thewateristhenheatedandanaciddetergentisadded.Thissolutioniscirculatedthroughout thecircuitwhilevalvesareperiodicallypulsedtoaidinsoilremoval.Duringthistimethebowl maybehandwashedifneeded. d. Analkalinecleaneristhenaddedtotheaciddetergentthatisbeingcirculated(causticoverride). Duringthistimetheheatismaintainedandthevalvescontinuetopulseperiodically. e. Thewashcycleisfollowedbyawaterrinsewhichoverflowsthebowlandcoolsdownthecircuit. f. Finallyanacidsanitizerisaddedandcirculatedthroughoutthecircuit.Thissanitizerremainsin thesystemuntiltheequipmentisusedagain. g. Thelineconnectionsarereturnedtotheiroriginalconfiguration. PriortotheequipmentsnextuseaCIPsanitationstepusinganacidsanitizerisperformed. a. Theresidualacidsanitizer(fromstep3fabove)isrinsedoutwithwater. b. Afreshsolutionofacidsanitizerispreparedinoneofthemixingtanks. c. TheHTSTisstartedupusingitsproductsetting(notCIP)andhighspeed.Thiswillpumptheacid sanitizerfromthemixingtankthroughalloftheequipmentthatisscheduledtobeusedthatday. c.

4.

CLEANINGOFBURNEDONRESIDUE
1. 2. 3. 4. Rinseoutresidualproduct. Fillthetankwithwaterandaddapowderedchlorinateddetergent. Heatthesolutiontoapproximately180Fandallowittosoakuntiltheresidueissoftenedandabletobe removed. MakethenecessaryCIPlineconnectionsandinitiatetheappropriateCIPprogram.

CLEANINGANDSANITATIONOFICECREAMPROCESSINGEQUIPMENT
1. 2. TheicecreammixtanksarecleanedusingthepasteurizedCIPcircuitdescribedabove. Theflavorvatsandicecreamfreezersarerinsedwithwaterfollowingeachuse.Thenasolutionofhot waterandchlorinatedalkalinedetergentiscirculatedthroughthisequipmentandthelinesconnecting them.Followingthecleaningsteptheequipmentisrinsedwithwater. Priortoeachdaysoperationsthepasteurizedlines,flavorvats,freezers,ingredientfeeder,halfgallonand threegallonfillingequipment,aswellasallthelinesconnectingthisequipmentaresanitizedwitha chlorinesanitizer.Residualsanitizerisflushedoutofthelinesbypumpingapproximatelythreegallonsof icecreammixthroughthecircuitanddrainingitontothefloor.Ondayswhenthedixiecuporpintfilling equipmentisuseditislikewisesanitizedpriortousewithachlorinesanitizerwhichisallowedtodrainto thefloor. Aftereachuse,thefillingequipmentisrinsedwithwatertoremovemostoftheresidualproduct.Thenit ishandwashedwithachlorinatedalkalinedetergentandrinsedwithwateragain.Additionally,atthe endofeachweekthefillingequipmentthathasbeenusediswashedusingaselffoamingchlorinated alkalinedetergentandrinsedwithwater.

3.

4.

CLEANINGANDSANITATIONOFBEVERAGECONTAINERFILLINGEQUIPMENT
1. 2. ThefillinglinesandequipmentarecleanedandsanitizedusingthepasteurizedCIPcircuitdescribed above. Ondayswhendairyproductsarepackagedthefollowingadditionalcleaningandsanitizingstepsare preformed. a. Priortopackagingtheacidsanitizerwhichwasretainedinthefillerbowlsisdrainedthroughthe fillertubesandontothefloor.Thenozzleheadsarealsosprayedwithanacidsanitizer.

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Atchangeovers(whenoneproductsisfinishedbeingpackagedandanotherbegins),theproduct remaininginthebowlisexpelledthroughthefillertubes.Theareaisthenrinsedwithwaterand sprayedwithanacidsanitizer. c. Whenpackagingisfinished,theproductthatremainsinthebowlisexpelledthroughthefiller tubesandtheareaisrinsedwithwater.ThebowlisflushedwithwaterandtheCIPconnection tothefillerheadsismade.Allexteriorsurfacesarefirsthandwashedwithachlorinatedalkaline detergent,thenwashedwithaselffoamingchlorinatedalkalinedetergentandrinsedwithwater. Ondayswhennondairyproductsarepackagedthefollowingadditionalcleaningandsanitizingstepsare preformed. a. Priortopackaging,theacidsanitizerwhichwasretainedinthefillerbowlsisdrainedthroughthe fillertubesandontothefloor.Anewsolutionofacidsanitizerispreparedinamixingtankand pumpedthroughalloftheequipmentandtanksthatwillbeusedthatday.Itisalsoallowedto overflowthebowlandflowthroughallofthefillertubes.Pasteurizedwateristhenpumped throughalloftheequipment,bowlandfillertubes.Thenozzleheadsaresprayedwithanacid sanitizer. b. Atchangeovers,theproductremaininginthebowlisexpelledthroughthefillertubes.Thearea isthenrinsedwithwaterandsprayedwithanacidsanitizer. c. Whenpackagingisfinishedtheproductthatremainsinthebowlisexpelledthroughthefiller tubesandtheareaisrinsedwithwater.ThebowlisflushedwithwaterandtheCIPconnection tothefillerheadsismade.Allexteriorsurfacesarehandwashedwithachlorinatedalkaline detergentandrinsedwithwater. b.

3.

CLEANINGANDSANITATIONOFCHEESEPROCESSINGEQUIPMENT
1. Cheddarandricottavats a. Thevatsaresanitizedpriortousewithanacidsanitizer. b. Afterusetheresidualproductisrinsedoutwithwater. c. Thevatsarethenfilledwithwaterandhandwashedusingbothapowderedchlorinated detergentandachlorinatedalkalinedetergent. d. Followingcleaning,thevatsarethoroughlyrinsedwithwater. Kettleandhomogenizer a. Priortousethekettleisfilledwithwaterwhichisheatedto180C.Thiswateriscirculated withinthekettle,pumpedthroughthelinestothehomogenizer,andthendrainedontothe floor. b. Followinguse,theresidualproductisrinsedoutofthekettlewithwater. c. Thekettleisthenfilledwithwaterandapowderedchlorinateddetergentandheated.This detergentsolutioniscirculatedwithinthekettle,pumpedthroughthelinestothehomogenizer, andthendrainedontothefloor. d. Additionally,thehomogenizerisdismantled,washedbyhandwithachlorinatedalkaline detergentandrinsedwithwater. Conebottomprocessorandpasteurizedstoragetank(PT6) a. TheconebottomprocessorandPT6aresanitizedpriortousewithanacidsanitizer. b. Followinguse,theresidualproductisrinsedoutwithwater. c. Thedoorgasket,filllines,andexteriorsurfacesarehandwashedwithachlorinatedalkaline detergentandrinsedwithwater. d. ThenthenecessarylineconnectionsaremadeandtheCIPprogramisactivated. Yogurtfiller a. Priortouseasolutionofchlorinatedalkalinecleanerispreparedandflushedfromthefiller bowls,overthetrackandthendrainedontothefloor. b. Followinguse,theresidualproductisrinsedoffwithwater.

2.

3.

4.

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TheremovablepartsofthefillerarecleanedinaCOPtubwithapowderedchlorinateddetergent andrinsedwithwater. d. Allexteriorsurfacesarehandwashedwithachlorinatedalkalinedetergentandrinsedwith water. Cheddarprocessingequipment a. Followingusethecheddarpressisrinsedwithwater,handwashedwithachlorinatedalkaline detergent,andthenrinsedagain. b. Thecheddarmillissanitizedpriortouse.Aftereachuseitisrinsedwithwater,handwashed withachlorinatedalkalinedetergent,andthenrinsedagain. c. Thevacuumpackagerissanitizedusingachlorinesoakedclothpriortouseandcleanedwithan aerosolcleanerfollowinguse. d. Thecheddarpansandlinersaredippedinasolutionofchlorinesanitizerpriortouse.Afteruse thelinersarediscardedandthepansarerinsedwithwater.ThepansarethencleanedinaCOP tubwithapowderedchlorinateddetergentandrinsedwithwater. c.

5.

VALIDATION
1. 2. 3. 4. Cleanedequipmentandutensilsarevisuallyinspectedtodetermineiftheyarefreeofresidueandforeign material. PeriodicswabbingofcleanedequipmentwithATPbioluminescenceswabsisusedtomonitorfoodcontact surfacesforthepresenceofresidualsoil. Swabbingwithmilkproteindetectingswabspriortothemanufactureofnondairydrinksisusedto monitorforpossiblecrosscontamination. SamplesareautomaticallycollectedfromthevariouscycleswithineachCIPprogram.Thesearetitrated todeterminetheirchemicalconcentration.Iftheconcentrationsarenotconsistentlywithinan acceptablerangethechemicalinjectiontimewillbeadjusted.

RECORDKEEPING
1. Resultsfromthechemicaltitrationsofcleaningandsanitizingsolutionsarerecordedonthesanitation testrecords.Thesetestsareperformedtodeterminetheconcentrationsofcleaningandsanitizing solutionsusedinboththeCIPsystemandtheCOPtubs. ResultsobtainedfromATPbioluminescenceswabsarerecordedonATPmonitoringforms. Resultsobtainedfrommilkdetectionswabsarerecordedontherecordsofmanufacturefornondairy drinks.

2. 3.

ThefollowingindividualisresponsibleforimplementationofthisSSOPandhastheoverallauthorityonsite: Name:____________________________Title:__________________________Date:_______________

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SSOP:003.003 SupersededSSOP:003.002 SupersedesSSOP:003.001 EffectiveDate:06/18/09 EffectiveDate:11/27/06 EffectiveDate:10/29/04

SANITATIONSTANDARDOPERATINGPROCEDURECrossContaminationPrevention

INTRODUCTION
Duringprocessingtherearenumerouswaysthataproductcanbecomecontaminatedwithamicrobiological hazard.Thethreemostcommonmeansofcrosscontaminationarecontactwithuncleanequipment,mixing pasteurizedwithrawproducts,andenvironmentalcontamination.

PROCEDURE
1. Periodicallymonitorequipmentsuchassilotanks,valves,agitatorshafts,shieldingandventingforcracks andcrevices.Improperweldsandirregularsurfacesaredifficulttocleanandsanitizeproperlyandthus canbecomeaharborageformicroorganisms. Producthandling: a. Minimizetheamountofafoodproductshandling,environmentalexposure,andtime/ temperatureabusefollowingpasteurization. b. Discardanyproductthathasbeenmishandled,notprotectedfromcontamination,ornot maintainedat45F(7.2C)orless. c. Whenreclaimingproducts,repasteurizationisrequired,usinghighertemperaturesand/or longerholdingtimes.Allequipmentinvolvedinthereclaimingprocessshouldbecleanedand sanitizeddaily. d. Isolatereturnedproductsandoutdatedproductsfromallotherplantoperations. Cleaningsupplies: a. Eliminatetheuseofabsorbentitemssuchasragsandspongesinprocessingareas,aswellas porousmaterialssuchaswoodenhandledtoolsandbrushes.Useimperviousmaterialssuchas metalorplasticinstead. b. Brushesshouldbesegregated;rawandpasteurized,internalandexternalsurfaces. c. Brushesshouldbemaintainedingoodcondition,sanitizedbetweenuses,andstoredproperly whennotinuse. Utilizeshieldingoverfoodandfoodcontactsurfacestominimizecontaminationwithcondensate, aerosols,dust,andotherairbornehazards. Monitorthecleanlinessofoverheadshielding,conveyors,conveyorbelts,chainrollersandsupports. Maintainacleaningandsanitizingregimenforallconveyors. Airblowandagitationequipmentshouldbemonitoredforcleanliness.Thesearenotusuallycleaned adequatelybyCIPmethodsandthereforeshouldbedismantled,cleanedmanually,andsanitizeddaily. Donotbreakorslashcontainersovertopavat. Exercisecarewhenhandlingpackingmaterials,especiallywhereopencontainersareconveyedthrough nonprocessingareas. Heating,ventilating,andairconditioningsystems: a. Shouldmaintainpositivepressureinareaswherefoodproductsareexposed. b. Minimizeairflowfrompotentiallycontaminatedareastoprocessingandpackagingareas.

2.

3.

4. 5. 6. 7. 8. 9.

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Outsideairshouldbefilteredandfreeofcondensate. Airflowshouldbecontrolledsothatitdoesnotblowdirectlyontofood,foodcontactsurfaces, aswellasfillingandpackagingareas. e. Airfiltersmustbeeffectiveinpreventingthepassageofmicroorganisms.Theymustalsobekept cleanandreplacedwhenneeded. f. Allheating,ventilatingandairconditioningsystemsshouldbeperiodicallycleaned,includingair systemsinrefrigeratedareas. g. Condensatedrippansanddrainlinesshouldberegularlymonitoredtoensuretheyarenot providinganenvironmentformicrobialgrowth. 10. Processairsystems: a. Systemsthatincorporateairdirectlyintothefoodproductmustbeeasilycleanedanddesigned tominimizecontamination. b. Processairsystemsshouldcontainfiltersthatarecapableofremovingextraneousmatter. c. Sanitarycheckvalvesthatpreventproductfrombackingupintotheairlinesshouldbeprovided whennecessary. 11. UseofpushcartsintheFoodScienceBuilding: a. ThereisariskofcrosscontaminationwhenpushcartsareremovedfromtheCreameryandused totransportitemstothethirdandfourthfloorsintheFoodScienceBuildingandviceversa. ThereforepushcartsusedintheCreameryprocessingplant,FoodSciencepilotplantsand sensorylaboratorywillhavebluetapeontheirhandles,andpushcartsforthethirdandfourth floorswillhaveredtapeontheirhandles. b. Bluelabeledcartsareusedtotransportfoodandfoodingredientsonthefirstandsecondfloors. Inordertoimprovebarrierhygienemethodstheyshouldnotbetakentothefourthfloor. c. Redlabeledpushcartsshouldnotcomeindirectcontactwithanyfoodoringredients.Items sentorshippedtothethirdandfourthfloorsshouldbetransportedonredlabeledcartsora dolly.Ifthesecartsareusedtotakesuppliesfromtheloadingdocktothethirdandfourth floors,theyshouldnotleavetheimmediatevicinityofthefreightelevator.Whennotinusered labeledcartsshouldbestoredonthethirdfourthfloors. d. Containers,samples,ingredients,packagesandlaboratoryequipmentshouldnotbetransferred fromonetypeofcarttoanother. e. Ifyouhaveanysafetyconcernsorthinkthataccidentalcrosscontaminationhasoccurred,call theCreameryofficeat8148657535immediately. ThefollowingindividualisresponsibleforimplementationofthisSSOPandhastheoverallauthorityonsite: Name:____________________________Title:__________________________Date:_______________ c. d.

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SSOP:004.002 SupersedesSSOP:004.001 EffectiveDate:11/27/06 EffectiveDate:10/22/04

SANITATIONSTANDARDOPERATINGPROCEDUREMaintenanceofSanitaryFacilities

INTRODUCTION
Theproductionofsafefoodbeginswithpropersanitation.Inadditiontocleanfoodprocessing equipment,thefacilitiesthatareassociatedwithfoodproductionareasmustbecleanandproperly maintained.

MATERIALS
1. 2. Cleaningequipmentandsupplies Chemicalcleaningagentsarestoredinlockedroomsawayfromfoodhandlingareas.

FACILITIES
1. Washrooms,lunchrooms,andchangingrooms: a. WashroomsaremaintainedbythePennsylvaniaStateUniversitiesOfficeofPhysicalPlant. b. Washrooms,lunchroomsandchangingroomsshouldbeseparatefromandnotleaddirectlyinto foodprocessingareas. Handwashingandsanitizingfacilities: a. Washroomsshouldhaveanadequatenumberofproperlymaintainedhandwashingfacilities thataredirectlyconnectedtosanitarydrains. b. Handwashingfacilitiesshouldhavehotandcoldpotablerunningwater,soap,sanitaryhand dryingsuppliesordevices,andcleanwastereceptacles. c. Processingareasshouldalsohaveanadequatenumberofconvenientlylocatedandproperly installedhandwashingfacilities. d. Itisrecommendedthathandwashingnoticesbepostedinstrategicpointsthroughoutthe processingplanttoremindemployeesandvisitorstowashhandsafterusingthebathroom.

2.

ThefollowingindividualisresponsibleforimplementationofthisSSOPandhastheoverallauthorityonsite: Name:____________________________Title:__________________________Date:_______________

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SSOP:005.001 EffectiveDate:12/20/06

SANITATIONSTANDARDOPERATINGPROCEDUREAdulterationPrevention

INTRODUCTION
Food,foodpackagingmaterialsandfoodcontactsurfacesmustbeprotectedfromadulterationwith physicalorchemicalhazards.Contaminantsmayincludewater,cleaners,sanitizers,lubricants,pesticides, metal,rubberandplastic.Theinclusionofunintendedingredientsandundeclaredallergensisalsoconsidered tobeproductadulteration.

GENERALADULTERATIONPREVENTIONPROCEDURES:
a. Reviewallpipingtoensurethatproductsarenotbeingcontaminated. a. Lookforlineswhereproducts,orcleaningandsanitizingsolutionscouldbecometrapped. b. Examinedrainlinestomakesuretheyaredrainingfreelyexceptduringuse. c. Monitorforcrossconnectionsbetweenrawandpasteurizedlines,betweenproductlinesand cleanedinplace(CIP)circuits. Inspectthesweetwatersystemandanyequipmentthatutilizessweetwaterforleaksandcracks. Monitorthewaterforharmfulcontaminants. Whenalterationsaremadeintheprocesspipingorequipment,changetheblueprintstoreflectthose alterations. Aspartofaroutinepreventativemaintenanceprogramexamineairvalves,screens,gaskets,seals,o rings,andothermetal,rubberandplasticpartsonprocessingequipmentforwear. Changethefiltersontheairblowsystemfrequently. Useextremecautionwhenreworkingproducts. a. Ensurethatallreclaimedproductshavebeenpasteurizedbeforereuse. b. Makecertainthatreclaimedproductisnotusedinthesamelinesorprocessingequipmentas pasteurizedproductunlesstheyhavebeencleanedandsanitizedbetweenuses. c. Donotreclaimproductsfromdamagedordirtycontainers. d. Donotreclaimproductsthatarebeyondthenormalshelflife. e. Donotreclaimproductsthathavebeenheldatelevatedtemperatures. f. Donotreclaimproductsthathavebeenexposedtochemicalorbiologicalcontamination.

2. 3. 4. 5. 6.

ALLERGENCONTROLPROCEDURES:
1. Utilizeproductandingredientlabels. a. Ingredientlabelsidentifyingallallergenicfoodsmustbeonallcontainersofferedforsale.The precautionarycontainsstatementmustbeclearlyvisibleaftertheingredientstatement. b. Recordallingredientsandtheirlotnumberontherecordsofmanufactureaswellasthelot numbersofallfoodcontactpackagingmaterials. c. Datecodingmustbeshownonallproducts. d. Ensurethatpackaginglabelsandingredientlabelsmatch. e. Allnewproductsandingredientsmustbereviewedforfoodallergensbeforetheirinitialuse.

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2. Cleaningandsanitationprocedures. a. Partsofprocessingequipmentthatrequiremanualcleaningshouldbethoroughlyinspected priortouse. b. TheCIPsystemmustbemonitoredforproperoperation,includingtime,temperature,chemical concentrationandflowrate.Adjustchemicalwasheswhenneededtoremoveheavyresidues. Documenttheresultsfromallchemicaltitrations. c. Dailyequipmentinspectionsshouldincludelookingforstuckvalves,incompletedrainageof tanksandimproperlinehookups. d. Verifytheeffectivenessofcleaningandsanitizing.ATPswabscanbeusedtomonitorsurface cleanliness,andmilkproteindetectionswabscanbeusedpriortomanufacturingnondairy products. Preventcrosscontamination. a. Allergencontainingproductsshouldbeproducedandpackagedonseparatedaysfromnon allergencontainingproducts.Ifthisisnotpossible,theyshouldbethelastproductsrunona productiondaythatalsopackagesnonallergenproducts. b. Afterprocessinganallergencontainingproducttheequipmentmustbecleanedandinspected priortousewithnonallergicproducts. c. Segregatedstorageofingredientsandutensilscanpreventcrosscontamination. Theuseofreworkshouldbecarefullymonitored. a. Productsduetobereworkedmustbeclearlylabeledandstoredatlessthan40Funtilused. b. Productsthatcontainallergensshouldonlybereworkedintoproductscontainingexactlythe sameallergen.

3.

4.

RECORDKEEPING
1. 2. 3. Recordsofmanufacturelistallingredientsandpackagingmaterialsaswellastheirlotnumbers.These areretainedforatleasttwoyears. Certificatesofanalysisforingredientsandpackagingmaterialsshouldbeobtainedfromsuppliers. Recordtheresultsfromthecleanerandsanitizerconcentrationassaysontheweeklytestform

REFERENCES
1. 2. ThefollowingindividualisresponsibleforimplementationofthisSSOPandhastheoverallauthorityonsite: Name:____________________________Title:__________________________Date:_______________ BerkeyCreameryFoodAllergenAwarenessPlan(mostrecentrevision) SSOP003CrossContaminationPrevention

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SSOP:006.002 SupersedesSSOP:006.001 EffectiveDate:11/27/06 EffectiveDate:07/20/04

SANITATIONSTANDARDOPERATINGPROCEDURELabeling,Storage,andUseofToxicChemicals

INTRODUCTION
Toxicchemicalsareroutinelyusedinallaspectsofthefoodmanufacturingprocess.Properlabeling, storageanduseofthesechemicalsminimizethechanceoffinishedproductcontaminationaswellasenhance employeesafety.

MATERIALS
1. Supplies

a. Gloves b. Goggles c. Spillcontainmentsupplies 2. Hazards a. Chemicalscancausedamagetoskinandeyes. b. Chemicalsusedinthemanufacturingandsanitationprocessesareapprovedforuseinthefood industry. PROCEDURE

1. Labeling: a. Allchemicals,includingmixedchemicals,shouldbeproperlylabeled. b. ChemicalwastesshouldbelabeledwithredtagssuppliedbyEnvironmentalHealthandSafety (EHS). Chemicalstorage: a. Chemicalsshouldbestoredandhandledinanareathatisdry,wellventilated,andseparatefrom foodhandlingareas. b. Allchemicalsaretobestoredsothatincompatiblesarenotnexttoeachother. c. Chemicalwastesshouldbestoredinprimarycontainersthatarecompatiblewiththewasteand leakproof.Theseprimarycontainersshouldbeheldinsecondarycontainmentinanapproved accumulationarea. d. Storedchemicalsmustbeinventoriedannually. e. ChemicalsnolongerinuseorpasttheirexpirationdatemustbemanifestedtoEHSfordisposal. Chemicalusage: a. Chemicalagents,includingdetergentsandsanitizers,shouldbeusedinamannerthatprevents contaminationoffood,packagingmaterials,andfoodcontactsurfaces. b. Chemicalsshouldbemixedandstoredinclean,labeledcontainers.

2.

3.

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4. Training: a. Chemicalsshouldbehandledbyproperlytrainedpersonnel. b. Within90daysofhire,allemployeesthatwillworkwithchemicalsarerequiredtoattendan initialtrainingprovidedbyEHS.Annualrefreshersforthattrainingaremandatory. c. MaterialsafetydatasheetsforthechemicalscurrentlyinusearelocatedintheCIProomorthey canbeaccessedontheinternet.

RECORDKEEPING
1. 2. 3. Chemicalandhazardouswastehandlingtrainingrecordswillbemaintained. Recordsoftheannualchemicalinventorywillbemaintained. Awastereviewlogwillbemaintainedateachaccumulationarea.

REFERENCES
1. PennStatesEnvironmentalHealthandSafetyOffice a. 6EisenhowerParkingDeck b. 8148656391 c. Fax:8148637427 d. www.ehs.psu.edu Materialsafetydatasheets

2.

ThefollowingindividualisresponsibleforimplementationofthisSSOPandhastheoverallauthorityonsite: Name:____________________________Title:__________________________Date:_______________

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SSOP:007.002 SupersedesSSOP:007.001 EffectiveDate:11/27/06 EffectiveDate:07/15/04

SANITATIONSTANDARDOPERATINGPROCEDUREControlofEmployeeHealthConditions

INTRODUCTION
Goodmanufacturingpractices(GMPs)areestablishedbytheFoodandDrugAdministrationanddetailed intheCodeofFederalRegulationstoprotectagainstcontaminationoffood.GMPsshallbefollowedbyall Creameryemployees,students,andvisitors.

MATERIALS
1. 2. 3. 4. Uniformsorlabcoats Shoesorboots Gloves Hairandbeardrestraints

HYGIENICPRACTICES
1. Handsaretobethoroughlywashedwithsoapandwarmpotablewateranddriedatthefollowingtimes,andas needed: a. Whenreportingtowork b. Afterabreakperiod c. Aftersmoking,eating,ordrinking d. Afterusingtoiletfacilities e. Atotherappropriatetimesasneededtomaintaingoodsanitation Eating,drinking,andgumchewingareprohibitedinfoodprocessingareas. Properhairrestraintsmustbeworn a. Hairrestraintmustcoverentirehead,includingthefrontandback b. Beardrestraintsmustbewornbyallemployeeswithmorethanonedaysgrowthoffacialhair, includingbeards,goatees,andsideburns. c. Mustachesthatgrowbelowtheliplinemustbecoveredwithabeardrestraint Fingernailsmustbeproperlygroomed;clean,cuttoanappropriatelength,withnopolishorartificial nails. Nowatchesorjewelry,exceptweddingringswithoutsets,arepermittedintheprocessingrooms. Smokingandtheuseofothertobaccoproductsareprohibited,exceptindesignatedoutdoorareas. Cleanuniformsaretobewornatthestartofeachshift,andleftonthepremisesattheendofeachshift. a. Uniformshirtsandlabcoatsmusthavesnapclosuresandnopocketsabovethewaistline. b. Shoes/bootsmustremainonthepremisesandsanitizedinafootbathwhenappropriate. c. Hats/bandanasthatarewornoverhairrestraintsmustbecleanandremainonthepremisesat theendoftheshift. Glovesusedinfoodhandlingshallbemaintainedinanintact,cleanandsanitarycondition.Theyshould bemadeofanimpermeablematerial. Personalbelongingsandstreetclothingshouldbestoredinanareaseparatefromfoodhandlingareas.

2. 3.

4. 5. 6. 7.

8. 9.

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INFECTIOUSDISEASEPOLICY
1. Employeesaffectedwithanydiseasecapableofbeingtransmittedtoothersthroughthecontaminationof food,foodcontactsurfaces,orfoodpackagingmaterialsshallbeexcludedfromanyoperationswhich maybeexpectedtoresultinthecontaminationoffinishedproductsuntiltheconditioniscorrected. Personnelshallreportsuchhealthconditionstotheirsupervisors.

2.

INJURY/OPENWOUNDPOLICY
1. 2. Employeeswithopensores,bleedingcuts,burns,orskininfectionswillnotbepermittedintheprocessing rooms. Somehandinjuriesmaybecoveredwithdisposablegloves,providedhandwashingproceduresare followed.

CONTROLLEDACCESSPOLICY
1. 2. 3. Accessofpersonnelandvisitorstoprocessing,packaging,andfinishedproductstorageareasshouldbe controlledtopreventcontamination. Allpersonnelandvisitorsmustabidebytheemployeegoodmanufacturingpracticeslistedinthesections above. Allnecessaryprecautionsneedtobetakentopreventcontamination,includingtheuseoffootandhand sanitizingsystems.

PERSONNELSAFETYPROGRAM
1. 2. OSHArequirementsforconfinedspacesallowaccessbyemployeestoconfinedspaces,whennecessary, formattersrelatedtotheoperationoftheprocessingfacility. OSHArulesoninjuryprotectionincludetheinstallationofdevices,suchasguardsandshields,toprotect personnelfrominjury.Hearingprotectioninareaswithhighlevelsofoperationalnoisewillreduce hearingrelatedinjury. Interiorairqualityrequirements.Adequateventilationandproperstorageofchemicalswillprevent unnecessaryairborneexposuretohazardousmaterials.

3.

REFERENCES
1. 2. 3. CodeofFederalRegulations a. Title21,Volume2,Parts100169(mostrecentrevision) EPAandOSHAregulationsrelatedtopersonnelsafety. PennStatesEnvironmentalHealthandSafetyOffice a. 6EisenhowerParkingDeck b. 8148656391 c. Fax:8148637427 d. www.ehs.psu.edu

ThefollowingindividualisresponsibleforimplementationofthisSSOPandhastheoverallauthorityonsite: Name:____________________________Title:__________________________Date:_______________

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SSOP:008.002 SupersedesSSOP:008.001 EffectiveDate:11/27/06 EffectiveDate:06/23/04

SANITATIONSTANDARDOPERATINGPROCEDUREPestControl

INTRODUCTION
Acommercialpestcontrolcompanyiscontractedtoprovidepestcontrolservices.Theyprovidepesticide applicationsonaroutinebasisforthetreatmentofinsectinfestations.Additionally,theyperformrodent controlproceduresinthebuildingexteriorareasaswellasareassuchasthetrashdisposalbinsandrecycling dumpsters.

MATERIALS
Equipment,supplies,andpesticidesarecompletelyunderthecare,custody,andcontrolofthepest controlcompany.Pesticidesareapprovedforuseinthefoodindustryandthehandleriscertifiedandholds anapplicatorslicense.

PROCEDURE
Serviceisperformedonamonthlybasis.Emergenciesarehandledpromptlyandmodernequipmentis used.Trainedprofessionalsperformservicesinasafemanner.Concernsandneedsarereadilyaddressedand thereareperiodicreviewsofthepesticideapplicationprogram.

RECORDKEEPING
Allservicereportsaremaintainedforatleasttwoyears. ThefollowingindividualisresponsibleforimplementationofthisSSOPandhastheoverallauthorityonsite: Name:____________________________Title:__________________________Date:_______________

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