HACCP System for Traditional African Fermented Dairy Products:

MANUAL
For
Ergo Production

Frew Tekabe and Almaz Gonfa

May 2000

Ethiopian Health and Nutrition Research Institute

(EHNRI)
World Association of Industrial and Technological Research Organizations (WAITRO
)

Hazard Analysis
And
Critical Control Point (HACCP) Based Quality System for the Production
of
Milk and Milk Products

MANUAL
For
Ergo

by
Frew Tekabe and Almaz Gonfa

May 2000
Ethiopian Health and Nutrition Research Institute (EHNRI)
Addis Ababa
World Association of Technological and Industrial Research Organizations (WAITRO
) Denmark

Acknowledgement
This manual has evolved from a joint research project titled "Capability Buildin
g for Research and Development in Traditional Fermented African Dairy Products"
coordinated by the World Association of Industrial and Technological Research O
rganizations (WAITRO). The project (Project No: ERBIC18CT960119) was sponsored b
y the European Commission, Directorate General XII: Science, Research and Develo
pment, RTD: Co-operation with Third Countries and International Organisations (I
NCO DC). The project involved the participation of the following institutions:
UGANDA INDUSTRIAL RESEARCH INSTITUTE Food Science and Technology Divisio
n, UGANDA
ROYAL VETERINARY AND AGRICULTURAL UNIVERSITY Department of Dairy and Foo
d Science, DENMARK
FEDERAL RESEARCH CENTER FOR NUTRITION Institute of Food Science, Hygiene
and Toxicology, GERMANY
ETHIOPIAN HEALTH AND NUTRITION RESEARCH INSTITUTE (EHNRI), Food Science
and Nutrition Department, ETHIOPIA
FOOD RESEARCH CENTRE, Animal Products Technology Section, SUDAN
The EHNRI project partners wish to acknowledge with thanks the contributions of
WAITRO, EU, the partner institutions and the scientists involved in the project.

Frew Tekabe
Almaz Gonfa
EHNRI

Table of contents
SECTION ONE
Application of HACCP to Ergo Processing
1.1 Introduction ……………………………………………………………………….... 1
1.2 Ergo ………………………………………………………………………………... 3
1.3 Hazard Analysis Critical Control Point (HACCP) …………………………………. 5
1.4 Key Concepts of HACCP ………………………………………………………….. 5
1.5 Principles of HACCP ………………………………………………………………. 6
SECTION TWO
The HACCP Manual .
Part I. Management of the HACCP System ……………………………………………. 7
Part II. Procedures for Supervisors …………………………………………………….. 19
Part III. Instruction for Production …………………………………………………….. 35
Forms ........…………………………………………………………………………….. 29
Reference:.. ……………………………………………………………………………..36

SECTION ONE

APPLICATION OF HACCP TO
ERGO PROCESSING

1.1. INTRODUCTION
Ethiopia is a country with a large livestock population that makes it first in t
he Sub-Saharan Africa and among the top ten in the world. Milk and milk products
are among the major products of the sector.
In Ethiopia, milk is produced in most Agricultural production systems and is an
important product in most pastoral and agro - pastoral systems in areas with hig
h human population density as the case in all other African countries.
In these production systems, milk and its products have an important place in th
e traditional diet of the people and are one of the staple foods among other tra
ditionally fermented agricultural products. In many instances, milk is also a so
urce of cash for the family. Milk is either sold and consumed fresh, as fermente
d milk or manufactured into products such as butter, gee and cheese.
Ergo, fermented milk, is the most common product consumed in the household or fu
rther processed into other products like butter, cottage cheese and whey. Ergo i
s traditional fermented milk that has some resemblance to Yogurt. It is produced
by natural fermentation of raw milk of cattle in all parts of Ethiopia by small
-hold farmers. Ergo is also made from milk of goat and camel in the pastoral reg
ion in relatively low amount. It has special status in the small-hold farming co
mmunities prevailing in agro-pastoral and pastoral systems of the country. In th
ese production systems, it is one of the staple diet and in many instances, a ma
jor source of cash for the family due to the fact that it gives way for further
processing of other more stable products which could be sold in the market and g
enerate income. Ergo is consumed as side-dish with different traditional foods,
spiced or non-spiced. It can also be used alone as food or drink.
Generally, fermented dairy products constitute the major part of the traditional
fermented foods utilized in Ethiopia. The various traditional methods used to p
repare different traditional fermented foods in general and fermented dairy prod
ucts in particular as well as the importance they have in the diet has a major s
ocial and cultural values of the country. Traditional methods of fermenting all
kinds of foods in Ethiopia are believed to improve the quality, variety as well
as shelf-life of each fermented product. These positive sides of the arts of tra
ditional fermentation methods handed over from generation to generation needs to
be promoted, improved and upgraded. The continuity of these methods has to be s
ecured in integrated and strengthened forms.
With an understanding of the major role played by fermentation in the traditiona
l method of food processing, many scientific researches have been carried out in
the former Ethiopian Nutrition Institute (ENI) on different traditional ferment
ed foods as well as on different methods of their processing. Currently, researc
h work is being conducted on traditional dairy products with the major objective
s of understanding principal underlying fermentation processes, isolating and de
veloping starter cultures, introducing GMP, as well as improving and upgrading f
ermentation of Ergo. These efforts have resulted in the isolation and developmen
t of indigenous starter cultures and their application in the local dairy plants
. A quality system has been established and implemented to ensure the microbiolo
gical safety and organoleptical quality of fermented dairy products such as Ergo
.
The quality system is described in this manual and based on the concept of Hazar
d Analysis Critical Control Point (HACCP) which has been combined with some sele
cted managerial and structural elements of the ISO 9000 system. The quality syst
em can be implemented by both traditional processors and entrepreneurs at minima
l cost and can be applied methodologically during Ergo production from the acqui
sition of the raw materials, fresh raw milk as well as water, through all the va
rious stages of processing to produce Ergo of improved quality.
This manual describes the steps of the unit operations involved in Ergo producti
on, the state of the art of quality system in the Ethiopian dairy plant, the HA
CCP quality system and direction for implementing HACCP in Ergo production. It d
raws on the experiences of the Ghana Food Research Institute in establishing an
HACCP system for processing traditional fermented food at small scale commercial
production plant.
The target groups of this manual are commercial dairy production plants, organiz
ations involved in dissemination of technology and promotion of small scale food
processing activities and HACCP experts who may be consulted to implement HACCP
in dairy processing plants. The manual will also be used during the training of
commercial dairy producers and entrepreneurs at the Ethiopian Health and Nutrit
ion Research Institute. The principles set out in the manual can be applied to i
mplement HACCP in other areas of food processing sector including both tradition
al as well as industrialized food processing activities.
1.2. ERGO
In Ethiopia, since there is only few industrial milk processing plants, the milk
produced by small-holder is processed on farm using traditional dairy technolog
y, as all other traditional fermented foods in the region.
In the traditional production system, processing Ergo (fermented milk products)
is mainly the responsibility of housewives, who also receive the income from sal
es of these products.
As mentioned above, the typical raw material for production of Ergo is fresh mil
k from cow. But in rare cases goats and camel milk is also used. Fresh milk fro
m the cow is collected in traditional equipment and left for fermentation. In mo
st cases, pre-smoking is applied to these equipment.
In the traditional processing, no inoculation of starters is required for Ergo p
reparation since natural spontaneous fermentation is the driving force. However,
in rare cases, back slopping is also used to provide a starter.
At ambient temperature of 16 to 180c milk is stored in smoked vessels takes 2-4
days to ferment. If the temperature during incubation is too high, fermentation
is rapid, causing a separation of the liquid and solid phase (called wheying off
) and gas production.
The pH; of traditional fermented Ergo is low, varying from 4.1 to 4.5. the low p
H is found to be important for its further storage.
Ergo is also produced by spontaneous fermentation in urban areas at home level u
sing cans or glass containers and without application of smoke to the containers
. However, in contrast to Ergo that is produced in traditional equipment with ap
plication of smoke, Ergo fermented in cans or glass containers can only be store
d for short period without spoilage unless refrigerated.
Generally, traditional methods of processing that are relatively inefficient and
time consuming, are used to convert fresh milk into Ergo and other products lik
e Ayib, Kibe, etc. In this system, the duration of processing also vary from hou
sehold to household.
The extremely perishable nature of fresh milk in conjunction with virtual absenc
e of modern procurement and marketing infrastructure in terms of transport, refr
igeration facilities, collection center and processing plant may inhibit the pro
duction of hygienic dairy products in rural areas. Unhygienic milk production an
d processing result in products with variable characteristics and short shelf li
fe.
This manual describes the unit operations involved in Ergo processing. It can we
ll be applied to other dairy products as well.
Hazard Analysis and Critical Control Point (HACCP)
Hazard Analysis and Critical Control Point (HACCP) is a quality system which aim
s at the production of microbiologically safe products of defined quality specif
ications by controlling the quality of raw materials and processing operations.
HACCP is a preventive method, which is systematically applied during food handli
ng and processing by relying on the anticipation, identification and assessment
of microbiological hazards as a preventive measure to provide safe food. Because
HACCP does not rely on elaborate laboratory analysis of finished products, its
principles can be incorporated into various levels of food processing operations
and scenarios. For instance in the semi-urban and rural setting in Ethiopia whe
re there are no facilities available for analyzing food, the HACCP concept can b
e carried out in a food processing unit by relying on visual observation of proc
essing materials and unit operations. Simple tests such as time/temperature moni
toring and determination of pH can also be performed on site. The HACCP concept,
therefore, offers the opportunity to integrate formal management of quality int
o traditional and non-traditional food processing and preparation in Ethiopia.
The Key Concepts of HACCP
Implementation of the HACCP quality system in food processing is based on certai
n key concepts and principles. For understanding the HACCP quality system, the f
ollowing basic terms are essential and are defined as follows:
Hazards are any biological, chemical or physical property that may cause an unac
ceptable health risk or quality defect in food. Their elimination or reduction t
o acceptable levels is essential for the production of safe food of defined qual
ity.
A Critical Control Point (CCP) is a raw material, location or process at which c
ontrol can be exercised to prevent or minimize a hazard.
Monitoring is a planned program of observations and simple checks of CCPs to ens
ure those critical limits are not exceeded.
Corrective measures are actions that are taken immediately when a CCP is monitor
ed and found not to be under control.
Verification is traditional laboratory analyses and audits carried out to ensure
that the HACCP system is working effectively.

Principles of HACCP
Implementation of HACCP is based on seven principles and for incorporation into
Ergo production these are defined as follows:

1. Hazards
Undesired microorganisms and quality defects associated with Ergo production.

2. Critical Control Points (CCPs)

Operational steps which can be controlled to eliminate or minimize the occurrenc
e of the identified hazards.

3. Critical limits
Target levels and tolerances, which should be met to ensure that each identified
CCP is under control. They are stated as physical, chemical, biological or sens
ory parameters which are easy and rapid to monitor such as appearance, odour and
pH.

4. Monitoring
A control plan is established to monitor each CCP to ensure that it is under con
trol, i.e. that the critical limits is not exceeded.

5. Corrective actions
Measures to be taken when the monitoring results show that a particular CCP is n
ot under control.

6. Documentation and record keeping system

Management's commitment, the system's procedures and working instructions are de
scribed and assembled in a manual. Results of monitoring, corrective action veri
fications and audit, training and management reviews are recorded on simple form
s and kept for a defined period of time.

7. Verification
Verification is carried out to ensure that the HACCP system is working correctly
through a review or audit of the system as well as chemical, physical and micro
biological analyses of raw materials, intermediary products and final products.
These tests can be performed by an independent institution such as the Quality a
nd Standards Authority of Ethiopia (QSAE) or the Ethiopian Health and Nutrition
Research Institute (EHNRI).

PART I

MANAGEMENT OF THE HACCP SYSTEM

The First Level of the HACCP system

This top level of the system documents the commitment of the Plant Owner/Manager
to the HACCP system and briefly states the quality objectives and policies of t
he enterprise. It outlines the obligations of the Plant Owner/Manager who will s
ign these documents to clearly demonstrate his commitment to the HACCP system. I
t will be accessible to all members of the HACCP team and be effectively communi
cated to all members of staff through training programmes. It contains 10 chapte
rs as described below:
MANAGEMENT OF THE HACCP SYSTEM
DATE: 15/08/98 REVISION NO: APPPROVED BY: The Plant Owner/Manager
TABLE OF CONTENTS

CHAPTER M.1 SCOPE

CHAPTER M.2 PLANT OWNER'S/MANAGER’S RESPONSIBILITY AND COMMITMENT
CHAPTER M.3 HACCP TEAM
CHAPTER M.4 CONTROL OF CCPS
CHAPTER M.5 MONITORING
CHAPTER M.6 HOUSEKEEPING, CLEANING AND HYGIENE
CHAPTER M.7 VERIFICATION AND AUDIT
CHAPTER M.8 CORRECTIVE ACTION
CHAPTER M.9 TRAINING
CHAPTER M.10 RECORDS KEEPING
Management of the Quality System
Date: 15/08/98 Revision No: Approved by: The Plant Owner/Manager
CHAPTER M.1.
SCOPE

The scope is to introduce, apply and maintain an HACCP system for the quality as
surance of Ergo, which is microbiologically, chemically and organoleptically saf
e and sound. The system will be implemented from the time of purchase and collec
tion of raw milk till the final product leaves the gate of the factory.
Management of the Quality System
Date: 15/08/98 Revision No: Approved by: Plant Owner/Manager
Chapter M.2.
MANAGEMENT RESPONSIBILITY AND COMMITMENT

The Plant Owner/Manager shall be committed and utilize the HACCP system to impro
ve the production of Ergo under sanitary environment according to the establishe
d processing methods. The final goal shall be to produce an improved and microbi
ologically safe and organoleptically sound product. The Manager shall work hard
to the strict application of HACCP system outlined and maintained. To meet the a
bove mentioned objectives, the Plant Owner/Manager shall offer the necessary fac
ilities, resources and regular training to improve (upgrade) the skill of the st
affs.

Management of the HACCP System

DATE 15/08/98 Revision No: Approved by: Plant Owner/Manager
Chapter M.3
The HACCP Team

To ensure effective implementation and maintenance of the system, the Plant Owne
r/Manager shall establish an HACCP Team, which shall include:
- Plant manager - Chairman
- Plant supervisor/Forman
- Dairy microbiologist - consultant
- Dairy Technologist - "
The Ergo HACCP team will have the following responsibilities: -
Describe the Ergo to be produced and its intended use.
Draw and appoint a flow diagram for the production of Ergo.
Identify the hazards in Ergo production as related to point 1.
Identify the CCP in Ergo production as related to point 1.
Describe the critical Limits (CLs) for each CCP
Establish procedures for monitoring the CCPs.
Establish the corrective actions to be taken when each of the CCP is outside the
range of the CLs.
Describe working instructions for production staff.
List all the laboratory analysis to be carried out for bi-annual verification of
the product quality and initiate audits.
Establish a record keeping system and design sample forms for recording, monitor
ing,
corrective actions, verifications, audit, training and management review.
The Ergo production HACCP team shall also be called upon when it is felt necessa
ry e.g. in case of major changes in the process, acquisition of equipment and em
ergence of new hazards.

MANAGEMENT OF THE HACCP SYSTEM

DATE: 15/08/98 REVISION NO: APPROVED BY: The Plant Owner/Manager
CHAPTER M.4
IDENTIFICATION AND CONTROL OF CCP

Because raw materials and operations in Ergo production are critical to the prod
uction of safe and good quality product, it is the responsibility of the HACCP t
eam to identify all CCPs and establish specific control measures to eliminate or
reduce the hazard defined to acceptable levels.
Management of the HACCP System
DATE: 15/08/98 REVISION NO. APPROVED BY: The Plant Owner/Manager
CHAPTER M.5
MONITORING

In order to guarantee that the identified hazards in Ergo production are adequat
ely controlled, monitoring shall be established for all CCPs to ensure early det
ection of any hazard or the failure of a particular control measure to reduce or
eliminate the hazard. Monitoring should have an effective reporting system to t
ackle with the problem and troubleshooting. To achieve this, the HACCP team sho
uld work out an effective control plan (CP). The Control Plan will include the c
ritical limits defined for earth CCP.
MANAGEMENT OF THE HACCP SYSTEM
DATE: 15/08/98 REVISION NO: APPROVED BY: The Plant Owner/Manager
CHAPTER M.6
HOUSEKEEPING, CLEANING AND HYGIENE

Following the Plant Owner s/Manager’s absolute commitment to maintaining a high

standard of hygiene and proper housekeeping, cleaning and disinfecting regimes w
ill be maintained to control undesirable micro-organisms. This will be in additi
on to adherence by staff members to established guidelines for personal hygiene
and health check-ups.
Management of the HACCP System
DATE: 15/08/98 REVISION NO. APPROVED BY: APPROVED BY: The Plant Owner/Manag
er
CHAPTER M.7
VERIFICATION AND AUDITS

The effectiveness of the established system should be verified by microbiologica

l and a chemical analysis of Ergo samples taken from identified CCPs as well as
final product. This task should be performed by a reputed and capable external l
aboratory invited by the Plant Owner/Manager. In case corrective action is requi
red, the plant owner/manager should take immediate and appropriate measure.
The plant Owner/Manager also shall organize a yearly external audit in addition
to the half-yearly Management Review.

MANAGEMENT OF THE HACCP SYSTEM

DATE: 15/08/98 REVISION NO: APPROVED BY: The Plant Owner/Manager
CHAPTER M.8
CORRECTIVE ACTION
To secure that defective products are not turned out, specific corrective action
s to be applied to each CCP when a control measure fails to reduce or eliminate
the identified hazard shall be established, i.e. when Critical Limits are exceed
ed. To enhance timeliness of all corrective measures, all non-conforming process
es and products shall be reported to the Plant Owner/Manager by the Foreman/Prod
uction Manager. The Foreman/Production Manager should carry out on-line correcti
ve actions required during production such as adjustments of equipment or extens
ion of fermentation period. Other corrective actions including those required af
ter verification, management reviews should be carried out by the HACCP team. Th
e team shall correct the relevant documents and new instructions shall be given
to the production staff.

Management of the HACCP System

DATE: 15/08/98 REVISION NO. APPROVED BY: The Plant Owner/Manager
CHAPTER M.9
TRANINING

Training of the production staff enables them to: -

Understand the hazards associated with Ergo production and the principles of HAC
CP
System.
Have a very clear understanding of their specific tasks and the skills required.
Fulfil their duties in the operation of the plant.
Understand hygienic conduct and food hygiene.
Thus, refresher and skill- upgrading course shall be regularly organized to upda
te the knowledge of workers. All newly employed staff shall have to undergo appr
opriate training before beginning work.
Training activities shall be recorded and the records kept by the Plant Owner/Ma
nager.

MANAGEMENT OF THE HACCP SYSTEM

DATE: 15/08/98 REVISION NO: APPROVED BY: The Plant Owner/Manager
CHAPTER M.10
RECORDS KEEPING

The Plant Owner/Mnager shall keep records of monitoring, corrective actions; aud
its, training and management reviews based on forms and format designed by the H
ACCP team. The forms and reports will be kept by a filing system established by
the team.
Forms for monitoring according to the Control Plan shall be completed by the Pla
nt Supervisor and filed by the Plant Owner. The Plant Owner/<manager files all r
eports of verification.
Part II.

PROCEDURES FOR SUPERVISORS

The second level of the HACCP system

The second level of HACCP system outlines the responsibilities of the Plant Supe
rvisor in the application and maintenance of HACCP principles in Ergo production
operations. To aid the supervisor carry out his/her responsibilities, this leve
l of the system describes the Ergo to be produced, procedures for control of CCP
s in the form of a Control Plan for verification drawn up by the HACCP team.
PROCEDERS FOR SUPERVISORS
DATE: 15/08/98 REVISION NO. APPROVED BY: The Plant Owner/Manager
TABLE OF CONTENTS

P.1. Production

P.2. Control Plan

P.3. Verification Plan

P.4. Final product specification

PROCEDERS FOR SUPERVISORS

DATE: 15/08/98 REVISION NO. APPROVED BY: The Plant Owner/ Manager
CHAPTER P.1
PRODUCTIION

It is the responsibility of the plant supervisor to ensure that every batch of E

rgo produced conforms to the product description and intended use stated below.
He/She shall ensure that the production produced used is in accordance with the
flow diagram elaborated by the HACCP team. The plant supervisor is also responsi
ble for meeting the final product specification.
Ergo is fermented milk product with a pleasant taste and flavors. It has a pH of
3.9 to 4.2 and contains 3.2-3.5/100g protein, 3.5/100g fat, 6.2/100g titrable a
cidity of 0.9-1.0%. Ergo should not contain more than 102 cfu/g aerobic mesophi
les and pathogenic bacteria shall be NIL/25g. Ergo can be consumed whole or furt
her churned to extract butter. It can also be used to extract Ayeb (soft cheese
) directly or after extraction of butter.
For the production of safe Ergo, the supervisor should fully understand all oper
ations in the production line to supervise and give the necessary support to the
workers.

PROCEDERS FOR SUPERVISORS

DATE: 15/08/98 REVISION NO. APPROVED BY: The Plant Owner/ Manager
PRODUCTIION/FLOW CHART
PROCEDERS FOR SUPERVISORS
DATE: 15/08/98 REVISION NO. APPROVED BY: The Plant Owner/ Manager
CHAPTER P.2
CONTROL PLAN

The supervisor shall monitor all CCPS according to the control plan worked out b
y the HACCP team and initiate on-line corrective actions when the critical limit
s are exceeded. The supervisor shall report all corrective actions to the plant
owner/manager who will decide on product conformance and further actions to be t
aken.
Monitoring results and corrective actions taken should be filed by completing th
e forms designed by the HACCP team. The completed forms shall also be handed ove
r to the Plant Owner/ Manager for filing on weekly basis.

PROCEDURES FOR SUPERVISORS

DATE: 20/08/98
APPROVED BY: The Plant Owner/Manager
CONTROL PLAN
PROCESS STEP (CCP)
HAZARD CONTROL MEASURE CRITICAL LIMITS MONITORING PROCEDURE CORRECTIVE ACTIO
N
RAW MILK
. Spoilage and pathogenic micro-organisms
. Antibiotic residues
. Adulteration (addition of powder milk)
. Purchase good quality fresh milk
Total solids
. Protein, 3-4 g/100
. CHO, 3.8-4 g/100
. Fat, 5.3-5.5 g/100
. pH, 6.5-6.6
. TA, 0.16-0.18%
. TAM, 105 /cfu/ml
. Pathogens and other indicators, NIL/25 g sample.
. No foreign odour
. Visual inspection
. pH strip
. Sensory
. Colour – white
. Odour - buttery
. Consistency – not sticky
. CMT test . Reject and inform supplier
. Education
. Change source of supply
. Pasteurization
Water used for cleaning the utensils . Spoilage and pathogenic micro-organism
s . Use clean water . Transparent
. Clear, odourless, clourless . Visual inspection . Boil the water before
use
. Educate supplier

24

CONTROL PLAN (contd.)

PROCESS STEP (CCP) HAZARD CONTROL MEASURE CRITICAL LIMITS MONITORING PROCE
DURE CORRECTIVE ACTION
Ergo fermentation . Mold growth
. Presence of spoilage pathogenic microorganisms . Adherence to t
ime-temperature control of fermentation . pH, 3.9-4.2
. TA (LA%), 0.90-1.00% . Visual inspection
. pH strip
. Sensory (color, taste etc) . If fermentation is slow, back-slop with old Er
go
. Reject bad quality
Packaging . Spoilage and pathogenic microorganism
s . Sterilization
. Good Hygiene . Spoilage and pathogenic microorganism
s NIL/25 g . Visual inspection . Reject
Ergo (final product) . Pathogens and other indicators NIL/25
g
. pH 3.9-4.2
. TA (LA) 0.9-1.00
. TAM (LAB) 108/cfu/ml
. CHO: 3.2-3.5/100g
Fat: 5.3-6.5
. Protein: 3.2-3.5

PROCEDURES FOR SUPERVISORS

DATE: 20/08/98
APPROVED BY: The Plant Owner/Manager
CONTROL PLAN
PROCESS STEP (CCP)
HAZARD CONTROL MEASURE CRITICAL LIMITS MONITORING PROCEDURE CORRECTIVE ACTIO
N
RAW MILK
. Spoilage and pathogenic micro-organisms
. Antibiotic residues
. Adulteration (addition of powder milk)
. Purchase good quality fresh milk
Total solids
. Protein, 3-4 g/100
. CHO, 3.8-4 g/100
. Fat, 5.3-5.5 g/100
. pH, 6.5-6.6
. TA, 0.16-0.18%
. TAM, 105 /cfu/ml
. Pathogens and other indicators, NIL/25 g sample.
. No foreign odour
. Visual inspection
. pH strip
. Sensory
. Colour – white
. Odour - buttery
. Consistency – not sticky
. CMT test . Reject and inform supplier
. Education
. Change source of supply
. Pasteurization
Water used for cleaning the utensils . Spoilage and pathogenic micro-organism
s . Use clean water . Transparent
. Clear, odourless, clourless . Visual inspection . Boil the water before
use
. Educate supplier

CONTROL PLAN (contd.)

PROCESS STEP (CCP) HAZARD CONTROL MEASURE CRITICAL LIMITS MONITORING PROCE
DURE CORRECTIVE ACTION
Ergo fermentation . Mold growth
. Presence of spoilage pathogenic microorganisms . Adherence to t
ime-temperature control of fermentation . pH, 3.9-4.2
. TA (LA%), 0.90-1.00% . Visual inspection
. pH strip
. Sensory (color, taste etc) . If fermentation is slow, back-slop with old Er
go
. Reject bad quality
Packaging . Spoilage and pathogenic microorganism
s . Sterilization
. Good Hygiene . Spoilage and pathogenic microorganism
s NIL/25 g . Visual inspection . Reject
Ergo (final product) . Pathogens and other indicators NIL/25
g
. pH 3.9-4.2
. TA (LA) 0.9-1.00
. TAM (LAB) 108/cfu/ml
. CHO: 3.2-3.5/100g
Fat: 5.3-6.5
. Protein: 3.2-3.5

PROCEDURES FOR SUPERVISORS

DATE: 15/08/98 REVISION NO: APPROVED BY: The Plant Owner/Manager
CHAPTER P 3.
VERIFICATION PLAN

The supervisor shall give assistance to the external laboratory in sampling mate
rials to be analyzed for verification and supply all necessary information for i
dentification of samples, etc. Verification shall be recorded on Form 3 and hand
ed over to the Plant Owner upon receipt of the analytical results.
PROCEDURES FOR SUPERVISORS
DATE: 15/08/98 REVISION NO: APPROVED BY: The Plant Owner/Manager
CHAPTER P.4
FINAL PRODUCT SPECIFICATIONS

It is the responsibility of the supervisor to ensure that the Ergo produced meet
s the following specifications:
. pH:- 3.9 to 4.2.
. TA:- 0.9 to 1.0 % ( as % LA).
. Protein:- 3.5 to 3.7 % in 100gms.
. CHO:- 3.2
. Fat:- 5.3 to 6.5 % in 100gms.
. TAM (Total Aerobic Mesophilic Counts including LAB) 108 /cfu/ml.
. Pathogenic micro-organisms:- NIL in 25gms of the product.
. Have typical organoleptic characteristics of Ergo.

NOTE:
Product specification for Ergo is subject to change in consultation with Quality
Standards Authority for Ethiopia.
PROCEDURES FOR SUPERVISORS

VERIFICATION PLAN
DATE: 20/08/98
REVISION NO. APPROVED BY: The Plant Owner/Manager
PROCESS STEP
LABORATORY ANALYSIS
RAW MILK COLLECTION Determination of pH, TS, TA.
Microbiological tests
. Viable count in cfu/ml
. Indicator/pathogen in cfu/ml
FERMENTATION
. pH test, TA, TS.
Microbiological tests
. Viable count in cfu/ml
. Indicator/pathogen in cfu/ml

FINAL PRODUCT (Ergo)

. pH test, TA, TS.

Microbiological test
. Viable count in cfu/ml
. Indicator/pathogen in cfu/ml
FORMS:

FORM 1
MONITORING OF CCPs
DATE: 15/08/98 BATCH NO. RECORDED BY: The Plant Owner/Manager
CCP
TYPE OF TEST TEST RESULTS
Raw milk Determination of pH, TS, TA.
Microbiological test
. Viable count in cfu/ml
. Indicator/pathogen in cfu/ml
Fermenting milk Determination of pH, TS, TA.
Microbiological analysis
. Viable count in cfu/ml
. Indicator/pathogen in cfu/ml
Ergo Determination of pH, TS, TA.
Microbiological analysis
. Viable count in cfu/ml
. Indicator/pathogen in cfu/ml
FORM 2
LIST OF CORRECTIVE ACTIONS
DATE
CCP CRITICAL LIMIT EXCEEDED
ACTION TAKEN
FORM 3
VERIFICATION RESULTS
DATE: 15/08/98 BATCH NO. RESULTS
Raw Milk Determination of pH, TS, TA.
. Fat
. Protein
. CHO
Microbiological test
. Viable count in cfu/g
. Indicator/pathogen in cfu/g
Ergo Determination of pH, TS, TA.
. Fat
. Protein
. CHO
Microbiological test
. Viable count in cfu/g
. Indicator/pathogen in cfu/g

Laboratory:
Date:
Signature of laboratory manager:

FORM 4
TRAINING
EMPLOYEE:
Name: ……………………………………
Period of employment.
TRAINING ELEMENT COMMENTS Date and Signature of Plant Owner/Manage
r
Understanding hazards associated with Ergo and the HACCP
Special tasks and unit operations
Milk collection
Transportation
Holding
Pasteurization
Inoculation
(Churning)
Fermentation
Packaging
Cleaning & disinfection

Hygienic conduct and basic food hygiene

FORM 5
MANAGEMENT REVIEW
Date of review:-……………………
Background material
Last Management Review report ......................................
Last External Audit report .................................................
Verification reports ..........................................................
Corrective action reports ..................................................
Customer complaints .......................................................
Others .........................................................................
.....

Main conclusions
................................................................................
...................................
................................................................................
...................................
................................................................................
....................................
................................................................................
....................................
................................................................................
....................................
Corrective actions and improvements instituted and persons responsible:
................................................................................
.......................................
Date and signature of Plant Owner ..............................................
................
Corrective actions effected ....................................................
..........

Date and signature of Plant Owner/Manager ......................................

.............

FORM 6

LIST OF CURRENT DOCUMENTS

Document Date of issue Date of latest revision Responsibilities
Distribution
PART III

INSTRUCTION FOR PRODUCTION STAFF

The Third Level of HACCP Manual

The third level of the HACCP manual, Instruction for Production Staff contain si
mple point by point work instructions on how various activities and operations a
t the milk plant are to be carried out in order to maintain the HACCP system.
Instructions for the operation of each equipment shall be pasted on the equipmen
t or nearby and instructions for other activities such as personal hygiene, plan
t cleaning and disinfecting/fumigation shall be posted on a notice board. The Pl
ant Owner or Manager shall file all the copies of instructions and a copy of the
complete set shall be kept by the supervisor.

INSTRUCTION FOR THE PRODUTIN STAFF

DATE: 15/08/98 REVISION NO: APPROVED BY: The Plant Owner/Manager
CLEANING AND DISINFECTION

Use conventional water treatment, cleaning and disinfecting principles and proce
dures applied to modern dairy plant.
Formulate an HACCP evaluation guidelines for water treatment, cleaning and disin
fecting each production line in Ergo plant.

Reference:
Bryan, F.L. (1992). Hazard analysis critical control point evaluations: A guide
to identifying hazards and assessing risks associated with food preparation and
storage, WHO, Geneva.