Quality Control & their CCPs - Milk Processing

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Quality Control & their CCPs - Milk Processing

Why Quality Control in Milk Processing Matters

Milk is a universal dietary staple, consumed by everyone from infants to the elderly. Its high perishability and sensitivity to contamination demand rigorous quality control (QC) and monitoring at every stage of processing.

QC in milk processing ensures:

Consumer safety and health
Product standardization and compliance
Prevention of spoilage and economic loss
Trust and brand protection

A food industry consultant helps design and implement end-to-end QC protocols that meet FSSAI, ISO, and Codex Alimentarius standards.

What Does Milk Processing Involve?

Milk processing typically transforms raw milk into:

Pasteurized milk
Butter, cheese, yogurt, and khoa
Milk powders and flavored milk

These processes may be semi-automated or fully automated and require high levels of hygiene and process control to maintain product integrity.

Quality and Safety Management Systems in Dairy Plants

Modern dairy processing units use a blend of systems such as:

HACCP (Hazard Analysis and Critical Control Point)
ISO 9000 Quality Management Systems
TQM (Total Quality Management)

These systems:

Ensure continuous monitoring
Provide traceability
Support corrective actions
Improve product shelf life and compliance

Benefits of Implementing Quality Control in Milk Processing

Quality Assessment in Milk Processing

1. Platform Tests for Raw Milk

Done at collection points
Include:
Clot-on-boiling test
Alcohol test
Organoleptic check
Temperature and acidity measurement

2. Adulteration Tests

Detect preservatives, starch, detergent, urea, and other banned substances
Colorimetric reactions indicate presence (e.g., rose-red to pink shift for preservatives)

3. Microbial Testing

Checks for:
Coxiella burnetii (improper pasteurization indicator)
E. coli (CIP failure)
Microbial load affects shelf life and safety

Quality Verification and Validation

Post-processing, products are validated against:

FSSAI limits for contaminants and composition
Codex Alimentarius standards for international exports
Shelf-life studies and sensory evaluations

Consultants often assist in setting up QA labs and establishing verification protocols with trained microbiologists and food analysts.

Critical Control Points (CCPs) in Milk Processing

CCPs are vital steps where control is essential to eliminate or reduce food safety hazards.

Key CCPs in Milk Processing

Process Flow with CCPs (Overview)

Reception and storage of raw milk
Standardization and filtration
Pasteurization
Homogenization (optional)
Filling and packaging
Cold storage and dispatch

Each step includes record-keeping, monitoring, and corrective actions in case of deviation from set parameters.

Conclusion: Quality Systems Build Dairy Trust

A well-designed QC system and CCP plan ensures:

Product integrity from farm to consumer
Fewer complaints, better shelf stability
Certification-readiness (FSSAI, ISO, Export audits)
Efficient use of resources and reduced waste

A seasoned food processing consultant supports dairy units with:

Plant-level HACCP implementation
Lab setup and validation checklists
Staff training on food safety and documentation

PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering Quality Control & their CCPs Milk processing Build World-Class Food Factories 1 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering CONTENTS 1 2 3 4 5 6 X Introduction Quality and Safety Management System Quality assessment at processing stage Quality verification/ validation CCPs in Milk Processing References About PMG Engineering Build World-Class Food Factories 2 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 1. Introduction Milk quality control involves processes to measure quality of milk at various processing stages. ✓ Purpose: Ensure safety, healthfulness, and adherence to required criteria for milk and milk products. ✓ Components of testing: Chemical composition, purity, and the presence of bacteria and other microorganisms. ✓ Stakeholders involved: Milk collectors, marketing and processors, organizations. ✓ Focus: Quality assurance through proper procedures. ✓ Key criteria: Safety, healthfulness, chemical composition, purity, and absence of harmful microorganisms. Build World-Class Food Factories 3 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 1.1 Milk Processing • Milk processing involves conversion of raw milk into - ✓ Pasteurized milk ✓ Milk products like powder, cheese, butter, and yogurt, etc. • Processing done using semi-automated and automated machinery. • An excellent control over quality is highly desirable, as milk is the only product which is consumed by all from infant/ children to senior citizens. Build World-Class Food Factories 4 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 2. Quality & Safety Management Systems For effective control over quality and safety of the milk products, the food sector employs several quality and safety management systems, including. Hazard Analysis and Critical Control Point (HACCP) Total Quality Management (TQM) ISO 9000, and others Build World-Class Food Factories Build World-Class Food Factories 5 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 2.1 Benefits of quality control system Milk Producers Milk processors Farmers can get fair prices Conformity of milk quality Consumers Fair payment as per quality of milk Government bodies Ensures •Consumer health •Fair pricing •Product safety Build World-Class Food Factories 6 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 3. Quality assessment 3.1 Platform test for Raw Milk • Dairy Product Quality is influenced by - ✓ Quality of raw milk used in manufacture, processing, and handling. ✓ Poor socio-economic conditions in rural producers check suitability/ To acceptability for processing, various quick quality tests named ‘platform test’ are done as mentioned in figure. 1. Visual and sensory tests Pleasant smell, White- yellowish tint colour 2. Sediment test < 0.5 mg (IS) 3. Clot-on- boiling (COB) test 4. Alcohol test Absence of Clots or Flakes on boiling Identifies aberrant milk i.e., colostrum 5. Alcohol– alizarin test Milk suitability for high heat treatment Build World-Class Food Factories Build World-Class Food Factories 7 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 3. Quality assessment 3.2(a) Adulteration Test: Detection of preservatives Rose red to pink colour Rose red to pink colour 2. Hydrogen Peroxide • Hehner and • Lech tests 1. Formalin/ formaldehyde P-phenyl diamine hydrochloride Turmeric paper 3. Boric acid/ borates Rose red to pink colour • Done for both raw milk and processed milk • Any kind of preservative/neutralizing agents shouldn’t be present, but some of additives can be present only if mentioned on label in various milk products 8 Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 3. Quality assessment 3.2(b) Adulteration Test: Detection of other adulterants Rose red to pink colour Rosalic acid solution test 2. Sugar Resorcinol sol test Blue colour 4. Urea Iodine Test DAMB test 1. Neutralizer 3. Starch Red colour Deep yellow colour Blue colour 2% DPA solution 5. Pond water Additive /adulterant Result/ Indication Build World-Class Food Factories 9 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 3. Quality assessment 3.3 Microbial Test • Quality of milk and milk products also lie on the microbial status In case of milk, • ✓ presence of Coxiella Burnetii in faults indicates pasteurization ✓ Presence of microorganism esp., indicates ineffective CIP coliform E.coli As a results, products quality may degrade before the general shelf life of the products Build World-Class Food Factories 10 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 4. Quality verification/ validation • After quality assessment of milk, quality, verification and validation of output as per the standard guidelines, is essential part of quality control. In recommended by government for result validations. India, FSSAI rules and regulation, & CODEX guidelines are • 11 Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 5. CCPs in Milk Processing Definition Effect Common CCPs Specific stage where safety precautions are taken to avoid, remove, or lessen any risks. • Crucial point to ensure milk product quality & safety CCPs include • Pasteurization, • Fermentation and, • Packaging Identifying and Monitoring • Maintaining quality, • Preventing contamination, • Guaranteeing safe, • wholesome milk production Build World-Class Food Factories 12 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 5.1 Process flow chart of Milk Processing with CCPs Receiving of Milk Filtration Chilling & Storage of raw milk Preheating at regen. 1 & 2 Homo- genization Cooling at < 4oC Pasteurization (HTST/LTLT/Fl ash) or UHT Clarification/B actofugation Storage in PMST at < 4oC Packaging (Pouch filling/ bottling) Transportation/ distribution critical control points critical points 13 Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 5.2 CCPs in Milk Processing with critical limit Processing Step/ Stage CCPs Issues (If CCPs not meet) Monitoring & correction measure Critical Limit k l i M f o g n i v i e c e R CCP 1: Raw Milk a. pH b. Specific gravity c. Temp. d. Freezing Point e. Microbial load a. Milk clotting on boiling b. Quality c. degradation Shorter shelf life d. Chances of adulteration e. Higher processing condition required • Checked by pH meter, lactometer, thermometer, freezing test, milko scan • Rejection of lot, accept if all condition meets. a. pH: 6.6-6.8 b. s. g: 1.028 -1.032 Temp: < 4oC c. d. F.pt: -0.53 to 0.575oC e. Microbial load:- • Total bacteria: 30,000/mL • Somatic cell count: < 750,000/mL Build World-Class Food Factories 14 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 5.2 CCPs in Milk Processing with critical limit (cont.) Processing Step/ Stage CCPs & n o i t a c i f i r a C l n o i t a g u f o t c a B n o i t a z i r u e t s a P CCP 2: Filtered raw milk a. Filter pore size b. Microbial load CCP 3: Pasteurized milk a. Process condition b. Target microbe Issues (If CCPs not meet) a. Pump clogging b. Shorter shelf life a. Shorter shelf life b. Food borne illnesses Monitoring and correction measure Critical Limit 1. Checked by Sampling, testing (including adulteration test, microbial test), 2. Faults corrected by re-processing etc.) a) Filter pore size: 100 – 200 µm b) TPC: 1.81 ± 0.72 log cfu/mL or 95.3 – 99% reduction. 1. Checked by Sensor based thermo-meter & sampling and testing, a) Conditions: - • 63oC/30min, • 72oC/15 sec, • 135oC/2- 3 sec 2. Corrected by re- pasteurization b) Coxiella burnetti: absent Build World-Class Food Factories 15 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 5.2 CCPs in Milk Processing with critical limit (cont.) Processing Step/ Stage Monitoring/ correction measure Issues (If CCPs not meet) CCPs Critical Limit n o i t a z i n e g o m o H i g n g a k c a P CCP 4: Homogenize d milk •Fat globule size • Non uniformity in milk constituent, • cream may separate out from milk CCP: 5 Packed milk •Packaging material • • Process contaminati on, Shorter shelf life 1. Monitoring done by sampling and testing fat globule size 2. Correction done by re- homogenization 1. Monitoring whole process of sterilization of packaging material and their processing environment, 2. Usage of food grade packaging material Fat size: 0.2 – 2 µm 1. Food grade packaging material 2. Food grade sterilizing components Build World-Class Food Factories 16 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 6. Reference • Griep-Moyer, E. R., Trmčić, A., Qian, C., & Moraru, C. I. (2022). Monte Carlo simulation model predicts bactofugation can extend shelf-life of pasteurized fluid milk, even when raw milk with low spore counts is used as the incoming ingredient. Journal of Dairy Science, 105(12), 9439-9449. • FAO. 1998. Milk Testing and Quality Control. Milk Processing Guide Series. Volume 2. FAO/TCP/KEN/6611 Project. Training Programme for Small Scale Dairy Sector and Dairy Training Institute – Naivasha. Kenya • Dairy production and products: Quality and testing (fao.org) • https://www.scielo.br/j/sa/a/tLWrMkgCycV3hSSFmhMp8fy/# • https://www.researchgate.net/figure/Flow-chart-indicating-the- presumptive-Critical-Control-Points-CCPs-for-microbial- hazard_fig1_342838484 Build World-Class Food Factories Build World-Class Food Factories 17 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering Our Clients Build World-Class Food Factories Build World-Class Food Factories # We deliver End-to-End Engineering Design and Construction Management Projects in Food and Beverage Industry. Meeting Global Benchmarks In ENGINEERING DESIGN and PROJECT MANAGEMENT for FOOD and BEVERAGE Industry with SINGLE POINT ACCOUNTABILITY Process Engineering | Project Management | Mechanical | Electrical | Automation | Food Safety Key Clients We deliver End-to-End Engineering Design and Construction Management Projects in Food and Beverage Industry. Meeting Global Benchmarks In ENGINEERING DESIGN and PROJECT MANAGEMENT for FOOD and BEVERAGE Industry with SINGLE POINT ACCOUNTABILITY Process Engineering | Project Management | Mechanical | Electrical | Automation | Food Safety Key Clients We deliver End-to-End Engineering Design and Construction Management Projects in Food and Beverage Industry. Meeting Global Benchmarks In ENGINEERING DESIGN and PROJECT MANAGEMENT for FOOD and BEVERAGE Industry with SINGLE POINT ACCOUNTABILITY Process Engineering | Project Management | Mechanical | Electrical | Automation | Food Safety Key Clients

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