FAO - TCP/RER/3002d - GHP/HACCP component on SEE regional project

EXPLANATION OF THE PROCESS STEPS OF MILK RECEPTION

1) Churn reception The churns are off loaded from the truck, put on the conveyor belt. The caps are removed and put aside for cleaning. Samples of milk are taken from the churns. The product is tested on various parameters like temperature, dirt, antibiotics, cell count, etc. 2) Tipping The churns are turned and emptied. The churns are kept upside down so that the rest of the milk drips back through a pipe in the weighing bowl. 3) Weighing The milk reception is divided into 2 sections, each section is equipped with a bowl to weigh the incoming milk. Each weighing bowl represents the volume provided by 1 farmer. The weight will be registered. A sieve might be integrated in this part; in this case, a seperate process-step has to be included. Pumping The milk has to be stored temporarily in a Tank. For this reason the milk has to be pumped through a filter and a cooler into the tank. 5) Filtering Particles of dirt and pieces of foreign matter are captured through this filter. Basicly, it is a protective measure to prevent damage of equipment in the further processing . 6) Cooling The milk will be cooled in a Plate Cooler to a temperature of 4C. It is necessary to maintain this temperature to prevent the growth of spoilage- and pathogenic bacteria. 7) Cold storage The Milk is stored at a temperature of 4 C awaiting further processing. 8) Floating tank To continue processing, the milk is passed through a Floating tank which is also the return tank of the unpasteurised milk 9) Pumping The milk will be pumped through the pasteurizer, which consist of the clarificator, the regenerative elements of the pasteuriser and the homogeniser. The pump consist of the control loop for pressure control, a pressure transmitter, a controller and a pneumaticly controlled regulating valve.

10) Pre Heating

The milk is preheated up to 45C ( in this example) with the objective to achieve the optimum temperature for Clarification and Standardisation of the milk. 11) The Separator is used to separate the cream and carry out clarification simultaniously. Extraneous matter has to be removed from the milk. If not, it may appear as sediment in the liquid milk and as dirt in other products, especially after storage. Filtering is the simplest way to remove the inpurities, but it also has the disadvantage that all the milk has to pass through the dirt that accumulates on the filter and part of the extraneous matter will dissolve in the milk that passes through the filter. Moreover, micro organisms will be washed out of dirt. Bacteria present in clumps or in dirt particles will be dispersed throughout the milk. The milk and cream are seperated in the same equipment. 12) Pre Heating Further preheating is necessary to carry out the homogenisation. The product is preheated to 68 C which is the required temperature for homogenisation.
PT MERKADI Management Consulting

Dairy case A2-start

FAO - TCP/RER/3002d - GHP/HACCP component on SEE regional project

13) Homogenisation The objective of homogenisation is to reduce the size of the larger fat globules in milk, normally varying from 0,1 to 15 micrometres to less than 2 micrometers. This effectively prevents seperation. Homogenisation takes place UPSTREAM in the processing this means before pasteurisation. 14) Pasteurisation This step is necessary to kill all vegetative pathogenic bacteria. Pasteurisation takes place at 72 C for 15 seconds 15) Cooling The milk is cooled down in various stages in the regenerative of the pasteuriser. Finally, the milk is cooled down with ice water in the same pasteuriser equipment. The temperature to be achieved is 4 C . This temperature is necessary to prevent the growth of spoilage bacteria. 16) Cold storage The milk is temporary stored in a tank at 4 C awaiting further processing ( Filling in sachets) 17) Pumping For further processing the milk is pumped to the filling machine. 18) Coding The plastic is fed into the filling machine. Prior to the actual filling, the laminate is foreseen with an expiry date which is contact printed on the plastic. 19) Sterilisation of plastic The plastic foil is sterilised with an UV lamp. The machine is not running when the lamp is not switched and burning. 20) Filling The milk is filled in the Low density polyethylene plastic. The milk is filled in a 1 liter package. 21) Sealing The plastic is sealed longitudinal and on the top and bottom. At this stage samples are taken from the very first sachets and checked on pH, dilution and other parameters to ensure the safety and quality of the milk. 22) Secondary Packaging The plastic are packed in returnable plastic containers. These returnable plastic containers have to be cleaned & sanitised in advance. 23) Stacking The plastic containers are stacked on a pallet. 24) Cold storage The pallets are stored in the cold storage at a temperature of 4 C awaiting despatch 25) Despatch The pallets are foreseen with a label with product information and loaded into the trucks. 26) Distribution The pasteurised milk is distributed within 1 to 2 hours to the various outlets in the city with refrigerated trucks 4 C
Note: The process-steps and temperatures are examples and cannot be copied just like that.

PT MERKADI Management Consulting

Dairy case A2-start