Haccp yogurt en inglés

A HACCP STUDY ON YOGHURT MANUFACTURE

by

Kasthurie Hoolasi

submitted in part fulfilment of the requirements for the degree of

Master in Technology : Quality

in the Department of Operations & Quality Management in the Faculty of Commerce at the Durban Institute of Technology

Supervisor: Dr. J.F. Mostert

June 2005

APPROVED FOR FINAL SUBMISSION

J. F. Mostert

BSc,MSc(Agric), DSc(Agric) (Pret)

Date:

DECLARATION

The work described in this dissertation was carried out by the author in the Department of Operations & Quality Management, Faculty of Commerce, from 11 September 2001 to 15 October 2004 under the supervision of Dr J F Mostert.

These studies represent original work by the author and have not been submitted in any form to another TertiaryInstitution. Where use is made of the work of others, it has been duly acknowledge in the text.

3rd June 2005

i

ABSTRACT
The increasing awareness and demand of consumers for safe and high quality food have lead many companies to undertake a comprehensive evaluation and reorganisation of their food control systems in order to improve efficiency, rationalisation of human resources and toharmonise approaches. This evaluation in food control systems has resulted towards the necessity to shift from the traditional approach that relied heavily on end-product sampling and inspection and to move towards the implementation of a preventative safety and quality approach, based on risk analysis and on the principles of the hazard analysis critical control point (HACCP) system. Yoghurt is themost popular fermented milk world-wide; the estimated annual consumption in South Africa amounts to nearly 67 million litres. The aim of this study was to implement a HACCP program in a commercial yoghurt factory and then to evaluate the program during certain critical stages of the manufacturing process. A HACCP program was successfully implemented in a large commercial yoghurt plant within a oneyear period, using the SABS 0330:1999 Code of Practice, as a basis. The program was implemented within the framework of all applicable laws, by- laws, regulations and compulsory specifications. Management gave their support and provided the necessary resources for the implementation of the HACCP program. This was one of the key factors for the successful implementation of the program. The teammembers, selected by management, established, communicated and implemented the policies, procedures and systems. All hazards associated with each step in the process, and all measures that controlled each hazard, were documented. A proper record keeping system for the verification of all HACCP procedures, process monitoring records and corrective action records were also established. The identificationof the critical control points, as well as the keeping of records, played a major role determining the validity of the HACCP plan and also to prove that the products were produced safely. In this study, the presence of antibiotics, and foreign material in raw milk, effective pasteurisation and homogenisation, as well as maintaining the correct fermentation temperature, were identified as criticalcontrol points. Eight thousand five hundred and forty analyses were performed microbiologically, chemically and physically in total. Microbiologically and chemically there was a positive impact on the ii

raw milk quality after the implementation of HACCP. This was due to stricter controls in terms of GMPs, GLPs , GHPs and CCPs. From the results obtained on the final product evaluation, it isevident that the tighter controls that were implemented impacted positively on the chemical properties of the product in terms of percentage total solids as well as the viscosity and also on the microbiological quality of the product in terms of the yeast and mould counts. This has also contributed to a decrease in the number of customer complaints especially with regard to viscosity and souring...