Code of Practice For Pasteurization of Milk On Farms and in Small Dairies

Licensed Copy: Oxford Brookes ATHENS, Oxford Brookes University, 27/07/2009 23:19, Uncontrolled Copy, (c) BSI
BRITISH STANDARD
Code of practice for
Pasteurization of milk
on farms and in small
dairies
BS 7771:1994
BS 7771:1994
Committees responsible for this

British Standard
The preparation of this British Standard was entrusted by the Consumer
Products and Services Sector Board to Technical Committee AW/17, upon
which the following bodies were represented:
British Association for Chemical Specialities
Department of Agriculture Northern Ireland
Department of Health
Department of Trade and Industry (Laboratory of the Government Chemist)
Health and Safety Executive
Milk Marketing Board
Milk Marketing Board for Northern Ireland
Ministry of Agriculture, Fisheries and Food (ADAS)
National Farmers Union
Scottish Office Agriculture and Fisheries Department
Society of Dairy Technology
This British Standard, having

been prepared under the
direction of the Consumer
Products and Services Sector
Board, was published under the
authority of the Standards Board
and comes into effect on
15 October 1994
BSI 06-1999
The following BSI references
relate to the work on this
standard:
Committee reference AW/17
Draft for comment 90/50231 DC
ISBN 0 580 23401 0
Amendments issued since publication

Amd. No.
Date
Comments
BS 7771:1994
Contents
Page
Committees responsible
Inside front cover
Foreword
iii
Section 1. General
1.1
Scope
1
1.2
References
1
1.3
Definitions
1
1.4
International definitions
3
Section 2. United Kingdom and European Community legislation
concerning milk pasteurization
2.1
General
4
2.2
The Dairy Product (Hygiene) Regulations 1994
4
2.3
Council Regulation (EEC) No. 1411/71
4
2.4
The Consolidated Food Labelling Regulations 1994
4
2.5
Methods and conditions for milk pasteurization
(Council Directive EC 92/46)
4
2.6
Statutory requirements concerning the quality of milk
4
2.7
Documentation and records
7
2.8
Pasteurized semi-skimmed and skimmed milk
8
2.9
Pasteurized milk-based drink or milk drink
8
2.10
Health and safety
8
2.11
Advice
8
Section 3. Design, location and construction of dairy premises
3.1
General
10
3.2
Situation of units at the producer processors premises
10
3.3
Situation of units in the small pasteurizing dairy
11
3.4
General constructional recommendations
11
Section 4. Components and functions of equipment used for milk
pasteurization on farms and in small dairies
4.1
Holder (batch) pasteurization
13
4.2
HTST (continuous) pasteurization
13
4.3
Continuous flow shell and tube heat exchangers
15
4.4
Choice of pasteurizing plant, commissioning, pre-production
tests and preliminaries
24
Section 5. Pre-processing operations (reception, storage) and milk
handling before pasteurization
5.1
General
27
5.2
Raw milk quality
27
5.3
Bulk milk supplies
27
5.4
Protecting milk quality
27
Section 6. Operation of pasteurizing plant
6.1
Operating procedures
29
6.2
HTST plant operation: practical aspects of ensuring
efficient pasteurization
32
Section 7. Milk packaging, storage and handling
7.1
Milk packaging
35
7.2
Storage and handling of milk after packaging
37
Section 8. Hygiene management
8.1
Hazard Analysis and Critical Control Point system (HACCP)
38
8.2
Cleaning and disinfection of dairy equipment
38
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8.3
8.4
8.5
Fundamentals of the cleaning process

Fundamentals of the disinfecting process
Inspection and sampling procedures for determining the
hygienic condition of dairy plant
Section 9. Quality
9.1
Statutory tests applied to pasteurized milk
9.2
Tests undertaken to fulfil other statutory requirements
9.3
Frequency of sampling
9.4
Quality defects in pasteurized milk
Section 10. Plant maintenance and inspection
10.1
General
10.2
Inspection of equipment and premises
10.3
Items to be inspected and/or recorded
Section 11. Cleaning and disinfecting milk pasteurizing equipment
and ancillaries
11.1
General
11.2
Pumps and pipelines
11.3
Storage and transport tanks
11.4
Heat exchangers: holder (batch) plants
11.5
Heat exchangers: continuous flow plants
11.6
Cotton filter cloths
11.7
Separators
11.8
Homogenizers
11.9
Water softeners
11.10
Bottle-washing machines
11.11
Milk bottles
11.12
Milk bottle crates
11.13
Container-filling machines
11.14
Management of cleaning and disinfecting products
Annex A (informative) Legislation relating to milk products and health
and safety
Annex B (informative) Bibliography
Figure 1 Components of a continuous flow HTST milk
pasteurization system
Figure 2 General arrangement of a plate heat exchanger
Figure 3 Balance tank of HTST pasteurizer
Figure 4 Example of a HTST pasteurizer flow control unit
Figure 5 Components of a hot water set
Figure 6 Pneumatic operated flow diversion valve
Figure 7 Illustration of a thermograph chart
Figure 8 Service contract inspection. Location of plant items
Table 1 Methods and conditions for milk pasteurization
Table 2 Statutory requirements concerning the quality of raw and
pasteurized milk
Table 3 Summary of statutory requirements for milk pasteurization
Table 4 Summary of laboratory tests concerned with pasteurized
milk: causes of failure: remedial action
Table 5 Quality defects in pasteurized milk
Table 6 Inspection of milk pasteurization equipment and ancillaries
List of references
ii
Page
39
40
42
44
48
48
48
52
52
53
60
60
61
63
63
65
66
66
68
68
69
70
71
72
74
74
16
17
18
19
20
22
23
58
5
6
9
45
49
55
76
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BS 7771:1994
Foreword
This British Standard has been prepared under the direction of the Consumer
Products and Services Sector Board at the request in particular of the
Department of Health; Ministry of Agriculture, Fisheries and Food; the
United Kingdom Milk Marketing Boards and the National Farmers Union.
This code of practice is intended for the use of manufacturers, suppliers and
installers of equipment; for purchasers and producer processors or operators of
small dairies; and for those involved in the approval and checking of plant and
milk quality and safety.
As a code of practice, this British Standard takes the form of guidance and
recommendations. It should not be quoted as if it were a specification and
particular care should be taken to ensure that claims of compliance are not
misleading.
The BSI Committee wishes to acknowledge the assistance of the Society of Dairy
Technology who have given permission to use information from their
Pasteurizing Plant Manual in this text.
A British Standard does not purport to include all the necessary provisions of a
contract. Users of British Standards are responsible for their correct application.
Compliance with a British Standard does not of itself confer immunity
from legal obligations.
Summary of pages
This document comprises a front cover, an inside front cover, pages i to iv,
pages 1 to 76, an inside back cover and a back cover.
This standard has been updated (see copyright date) and may have had
amendments incorporated. This will be indicated in the amendment table on the
inside front cover.
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iii
iv
blank
BS 7771:1994
Section 1. General
1.1 Scope
This British Standard gives recommendations for
the process principles, design features and
operation of equipment used on individual farms by
producer processors and in small dairies for the
pasteurization of cows milk by means of the holder
(batch) and continuous flow (HTST) methods.
Guidance is given on the requirements of UK and
EEC legislation for dairies concerning pasteurized
milk. Guidance is also given on the hygienic and
control measures used in the pasteurization process
and packaging operations which are necessary to
achieve safety and high quality in pasteurized milk.
For convenience a list of the legislation referred to in
this standard is given in Annex A. A bibliography of
relevant publications is given in Annex B.
This standard does not cover specific
recommendations for the pasteurization of cream,
ice cream or flavoured milks.
NOTE Levels of heat treatment in this standard are not
necessarily appropriate for cream, ice cream and flavoured milks.
Separation of milk for other products should be undertaken
before pasteurization.
1.2 References
1.2.1 Normative references
This British Standard incorporates, by dated or
undated reference, provisions from other
publications. These normative references are made
at the appropriate places in the text and the cited
publications are listed on the inside back cover. For
dated references, only the edition cited applies; any
subsequent amendments to or revisions of the cited
publication apply to this standard only when
incorporated in the reference by amendment or
revision. For undated references, the latest edition
of the cited publication applies, together with any
amendments.
1.2.2 Informative references
This British Standard refers to other publications
that provide information or guidance. Editions of
these publications current at the time of issue of this
standard are listed on the inside back cover, but
reference should be made to the latest editions.
1.3 Definitions
NOTE The meaning of terms used in the United Kingdom
legislation concerning milk production, pasteurized milk,
semi-skimmed and skimmed milk and pasteurized milk-based
drink or milk drink, is given in individual items of legislation.
Persons responsible for milk production and milk processing
operations should be aware of the legal interpretation of the
terms used in dairy legislation.
For the purposes of this British Standard, the

following definitions apply.
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1.3.1
approved chemical agents
disinfecting agents or detergent/disinfectants
approved jointly for use in England and Wales by
the Minister of Agriculture, Fisheries and Food and
the Secretary of State for Social Services and the
Secretary of State for Wales
NOTE 1 Chemical disinfectant agents approved for use in
England and Wales may be used in Northern Ireland.
NOTE 2 In Scotland, the Secretary of State approves chemicals
for use as bactericidal agents in dairy applications.
1.3.2
available chlorine
the quantity of chlorine equivalent to the oxygen
released when the chlorine containing disinfecting
agent is completely decomposed to chloride and
oxygen
NOTE The use of the term available chlorine is confined in
practice to liquid hypochlorite and solid chlorine-releasing agents
in which the disinfecting action follows a ready hydrolysis to
hypochlorous acid and its subsequent decomposition to chloride
and oxygen.
1.3.3
buffering
stabilizing the pH value of a solution
1.3.4
chilled water
clean water at a temperature of less than 5 C
1.3.5
cleaning
the process of removing soil
1.3.6
cleansing
as in various milk and dairies legislation, a
combination of cleaning and disinfecting processes
1.3.7
clean water
water that, at the point of use, is of a quality
sufficient to conform to the classification set out in
the UK Water Supply (Water quality)
Regulations 1989 which implement the provisions
of EEC Directive 80/778/EEC 1980 Quality of water
intended for human consumption
1.3.8
coliforms
bacteria, which at 30 C, can ferment lactose with
the production of gas under the conditions specified
NOTE Coliforms do not survive pasteurization. They are
common contaminants of improperly cleansed equipment.
1.3.9
corrosion inhibitors
substances capable in specific instances of
minimizing the corrosion of certain metals
BS 7771:1994
1.3.10
dairy establishment
1.3.20
methylene blue test
dairy premises used for the treatment, processing,

collection or standardization of milk
a dye reduction test which measures the extent of

bacterial contamination and its activity in
pasteurized milk
1.3.11
detergents
substances capable of assisting cleaning when
added to water
NOTE They include soaps, organic surface-active agents,
e.g. synthetic detergents, alkaline materials and, in certain
circumstances, acids.
1.3.21
milk churn
synonymous term for milk can
1.3.22
milkstone
1.3.12
disinfection
a deposit that contains calcium caseinate and

calcium phosphate
a process that reduces the number of bacteria in

dairy plant and utensils to a level consistent with
acceptable quality control and hygienic standards
1.3.23
peroxidase test
1.3.13
disperse
to bring into (and keep in suspension) undissolved
soiling matter
1.3.14
emulsify
to bring into (and keep in dispersed form) oils and
fats from the milk residue
1.3.15
farm pasteurizer
term used in Northern Ireland to identify a milk
producer who processes and sells pasteurized
milk(s)
1.3.16
fogging
the application of a disinfecting agent in the form of
a dense mist of minute droplets
1.3.17
holder (batch) pasteurization
a non-continuous method of achieving
pasteurization conditions for milk and milk
products
1.3.18
HTST (continuous) pasteurization
the high-temperature short-time method for
continuous-flow pasteurization of milk and milk
products
1.3.19
keeping quality of pasteurized milk
the time required for pasteurized milk to become
unacceptable to a consumer, because of the
development of an undesirable off flavour or a
physical instability in the milk
a method which determines whether or not milk has

been heated during the pasteurization process to a
temperature above 78 C at which point the enzyme
is inactivated
1.3.24
phosphatase
an enzyme that is always present in raw milk and
that is inactivated by the time-temperature
combination necessary for pasteurization
1.3.25
plate count
the number of bacteria and other micro-organisms
which are present in a sample of milk and are viable
and countable under the conditions of the test
1.3.26
production holding
premises which have been approved for the
production and sale of raw milk
1.3.27
producer processor
a milk producer who processes and sells pasteurized
milk(s) through retail outlets such as shops
1.3.28
producer retailer
a milk producer who processes and sells pasteurized
milk(s) either retail direct to customers or
semi-retail to caterers, hospitals and other
institutions
1.3.29
psychrotropic bacteria
those bacteria which are capable of appreciable
growth at about 6 C, irrespective of their optimum
growth temperature
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1.3.30
sequestering agents
chemicals that combine with calcium and
magnesium salts, such as those occurring in hard
water, to form water-soluble compounds, generally
enhancing the detergent operation
1.3.31
soil
the milk residue, scale and other deposits of soiling
matter that have to be removed from plant and
containers during the cleaning process
1.3.32
sterilization
a process intended to destroy all living organisms
1.3.33
surface-active agents
substances capable of modifying the physical forces
existing at surfaces, such as between liquids and
solids, permitting more intimate contact and
facilitating their mixing
1.3.34
swabbing
the application of a liquid to a surface by means of a
cloth or other absorbent material
1.3.35
thermization
heating of milk for at least 15 s at a temperature
between 57 C and 68 C such that after treatment
the milk shows a positive reaction to the
phosphatase test
1.3.36
thermoduric bacteria
organisms which survive pasteurization
1.3.37
unopened pack
a completely sealed container, which has not had its
contents exposed to possible environmental
contamination
1.4 International definitions
NOTE Pasteurization is intended to avoid public health

hazards in the sense that, although it may not destroy all the
pathogenic microorganisms which may be present, it reduces the
number of harmful microorganisms to a level at which they do
not constitute a significant health hazard. Pasteurization also
extends the keeping quality of some products by reducing the
number of spoilage microorganisms in the product.
(IDF D-Doc 222:1991.)
1.4.2 A pasteurized product

A milk or a fluid milk product which has been
subjected to pasteurization, which if retailed as such
has been cooled without delay and has then been
packaged with minimum delay under conditions
which minimize contamination. The product must
give a negative phosphatase test immediately after
heat treatment.
NOTE A pasteurized product as defined is one which has been
pasteurized as such, as distinct from a product manufactured
from milk, skimmed milk and/or cream which has been
pasteurized.
A negative phosphatase test is considered to be

equivalent to less than 2.2 micrograms of phenol
liberated by 1 millilitre of sample (IDF
Standard 63:1971) or less than 10 micrograms of
p-nitrophenol liberated by 1 millilitre of sample
(IDF Provisional Standard 82A:1987).
(IDF D-Doc 170:1988.)
1.4.3 Process parameters
Various combinations of temperature and duration
of heating have an equivalent and minimum
bactericidal effect necessary for the pasteurization
of milk and skimmed milk. (IDF Bulletin 292/1994.
Recommendations for the hygienic manufacture of
milk and milk-based products.) These combinations
are 62.8 C for 30 min by the holder (batch) process
and 71.7 C for 15 s by the HTST (continuous)
method. In each case the milk is cooled without
delay preferably to 5 C or below.
Legislation requirements exist in respect of:
a) the temperature below which the product
needs to be cooled;
b) upper limits to the temperature of heat
treatment, and conformity to a test for the
presence of peroxidase.
1.4.1 Pasteurization
A heat treatment process applied to a product with
the aim of avoiding public health hazards arising
from pathogenic microorganisms associated with
milk. Pasteurization as a heat treatment process is
intended to result in only minimal chemical,
physical and organoleptic changes.
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BS 7771:1994
Section 2. United Kingdom and European

Community legislation concerning milk
pasteurization
2.1 General
The production and sale of pasteurized milk in the
United Kingdom is controlled by the general
provisions of the Food Safety Act 1990 for England,
Wales and Scotland, and the Food Safety (NI)
Order 1991 for Northern Ireland.
These Acts authorize Ministers to make regulations
controlling:
a) the conditions of milk production;
b) the approval and use of milk establishments;
and
c) the sale of milk within specified categories.
2.2 The Dairy Product (Hygiene)

Regulations 1994
These include the detailed provisions concerning a
registration to produce raw milk (production
holding) or an approval in relation to milk
pasteurization (dairy establishment).
General statutory requirements relate to:
a) health and housing of cattle;
b) buildings and water supplies;
c) arrangements for pest control;
d) handling, filtration, cooling and storage of
milk;
e) infection of milk and protection against
contamination;
f) cleansing and storage of vessels, utensils and
appliances;
g) hygiene applicable to staff, including training;
h) prescribed milk standards;
i) effective heat treatment;
j) packaging, labelling and transport.
Regulations with similar intent apply in Northern
Ireland and Scotland and should be consulted.
2.3 Council Regulation (EEC)

No. 1411/71
These regulations restrict the sale of milk for
human consumption to the following categories:
a) raw milk;
b) non-standardized whole milk;
c) standardized whole milk;
d) semi-skimmed milk;
e) skimmed milk.
2.4 The Consolidated Food Labelling

Regulations 1994
(currently undergoing public consultation)
These regulations require all milks to be correctly
marked and labelled when prepackaged and sold for
human consumption.
2.5 Methods and conditions for milk

pasteurization (Council Directive
EC 92/46)
The occupier of a dairy establishment should be
familiar with and undertake his operations
according to the requirements concerning the
pasteurization of milk in respect of
time/temperatures of heat treatment, control of the
pasteurization process, cleaning and disinfection,
milk storage and transport, milk quality and
packaging.
These are summarized in Table 1.
Attention is drawn to further requirements that:
a) the critical control points in the process are
identified, monitored and controlled to the
satisfaction of the approving authority;
b) such permanent records are retained, as
required by the approving authority.
2.6 Statutory requirements

concerning the quality of milk
Legal quality standards apply to raw milk intended
for heat treatment and to pasteurized milks.
In addition to microbiological standards, statutory
requirements include:
a) that milk does not contain added water,
antibiotic residues in excess of authorized levels
or residues of substances harmful to human
health;
b) that pasteurized milk has been subjected to a
permitted pasteurization procedure and satisfies
the specified phosphatase test;
c) that pasteurized milk shows a positive reaction
to the peroxidase test as specified or, in the case
of high temperature pasteurized milk, shows a
negative reaction to this test;
d) limits on the permitted storage time and
temperature of raw milk prior to heat treatment.
The occupier of a dairy establishment should be
aware of the statutory tests and the standards to be
achieved in order to implement an effective quality
control programme to ensure full compliance.
The statutory requirements are summarized in
Table 2.
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BS 7771:1994
Table 1 Methods and conditions for milk pasteurization

Legislation
UK legislation relating to pasteurized milk(s) prescribe the following:
Method and conditions of

heat treatment
Milk has to be pasteurized that is to say:

a) obtained by means of a treatment involving a high temperature for a
short time (at least 71.7 C for 15 s or an equivalent combination); or
b) a pasteurization process using different time and temperature
combinations to obtain an equivalent effect, e.g. batch pasteurization:
at least 62.8 C for 30 min;
c) cooled to a temperature not exceeding 6 C as soon as practicable
after pasteurization.
The heat-treatment equipment has to be approved by the competent
authority and fitted with:
1) an automatic temperature control;
2) a recording thermometer;
3) an automatic safety device preventing insufficient heating;
4) an adequate safety device preventing the mixture of pasteurized
milk with incompletely heated milk (HTST plants);
5) an automatic recording device for the safety system referred to in 4)
(HTST plants).
Cleaning and disinfection
Instruments and working equipment intended to come into direct contact

with raw materials and products, have to be smooth, corrosion resistant
and easy to clean and disinfect.
Equipment which comes into contact with milk during production has to
be cleaned and disinfected at the end of each working phase and at least
once each working day.
After chemical disinfection instruments and equipment have to be rinsed
with potable water.
Milk storage and transport
The temperature at which pasteurized milk may be kept until it leaves

the establishment has to be k 6 C and the storage temperature should
be recorded.
During transport the temperature of pasteurized milk cannot exceed 6 C
(this does not apply to doorstep deliveries to the consumer).
Vehicles and containers used for transporting pasteurized milk have to
be designed and equipped in such a way that the required temperature
can be maintained.
The internal surface of any vessel used to transport pasteurized milk has
to be smooth, corrosion resistant and easy to clean and disinfect.
Milk quality
The pasteurized milk has to meet prescribed quality standards.
Packaging, sealing and

labelling
Bottling, filling of containers with heat-treated milk and the sealing of

containers and of packaging has to be carried out automatically.a
Sealing has to be carried out in the dairy establishment in which the heat
treatment has been carried out immediately after filling.
The health mark, nature and date of heat treatment, storage
temperature and indication of durability have to be displayed.b
A derogation may be granted to establishments with limited production.
Special dispensations may apply.
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BS 7771:1994
Table 2 Statutory requirements concerning the quality of raw and pasteurized milk
Milk
Raw milk for the

manufacture of
drinking milk
Point of production
Milk storage
temperature
During transport
Upon reception at the
milk establishment
Pasteurized milk
(liquid
consumption)
Production line
Raw milk for the

manufacture of
milk-based
products
Point of production
k 8 C
(if not collected

within 2 h of
milking)
Test
Plate count at 30 C k 100 000/ml
Geometric average over 2 months;

at least two samples per month
Somatic cell count
k 6 C
(alternate day
collection)
If processed within 36 h
of acceptance at
processing
establishment
If processed within 48 h
of acceptance at
processing
establishment
k 400 000/ml
Geometric average over 3 months;

at least one sample per month
Antibiotics residues
Council Regulation
(EEC) 2377/90 (as amended)
prescribes maximum residue
limits
Added watera
Absent.
Confirmation by regular checks
and sample testing
k 10 C
k 6 C if not treated As above

within 4 h
As above
Plate count at 21 C < 50 000/ml (m)

after incubation
(n = 5, c = 1, M = 5 105)
at 6 C for 5 days
Coliforms
k 6 C
Absent (m)
(n = 5, c = 1, M = 5)
Pathogenic
micro-organisms
(n = 5, c = 0, M = 0)
As above
Added water
As above
Absent in 25 g (m)
k 8 C (if not
collected within 2 h
of milking)
Plate count at 30 C From 1.1.94 k 400 000/ml
k 6 C (alternate
day collection)
Somatic cell count
From 1.1.98 k 100 000/ml
Added water
During transport
Legal quality standards
From 1.1.94 k 500 000/ml

From 1.1.98 k 400 000/ml
As above
As above
k 10 C
k 6 C
k 4 C
Freezing Point Depression (FPD)

It is important to avoid confusing the freezing point of milk given above with the FPD as expressed using the Hortvet procedure. The
latter is commonly adopted in the United Kingdom resulting in a freezing point approximately 0.018 C lower, i.e. 0.538 C
(Hortvet). See BS 3095.
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Table 2 Statutory requirements concerning the quality of raw and pasteurized milk
Milk-based products
Type of micro-organism
Legal quality standards
Cheese other than hard cheese
Listeria monocytogenes
Absence in 25 g where
n = 5, c = 0
Milk-based products, other than

cheese covered above
Listeria monocytogenes
Absence in 1 g
Milk powder
Salmonella spp
n = 10, c = 0
Milk products, other than milk

powder
Salmonella spp
n = 5, c = 0
The samples of 25 g above have to consist of 5 5 g taken from different parts of the same product.
Where the above standards are exceeded the products are to be withdrawn from the market and not
permitted to be used for human consumption.
Soft cheese
Fresh cheese
Powdered milk
Frozen milk products including
ice-cream
Staphylococcus aureus
Escherichia coli
Staphylococcus aureus
n = 5, c = 2
m = 100, M = 1 000
n = 5, c = 2
m = 10, M = 100
Where the standards for the above four categories of products are exceeded a review of the monitoring
methods should be undertaken and the enforcement authority advised of corrective measures
implemented.
Whenever strains of enterotoxinogenic Staphylococcus aureus or strains of Escherichia coli which are
presumed to be pathogenic are identified in dairy products, all batches involved have to be withdrawn
from the market and the enforcement authority notified.
The symbols given in Table 2 have the following meaning:
n = number of sample units comprising the sample;
c = number of sample units where the bacteria count may be between m and M, the sample being considered acceptable if the
bacteria count of the other sample unit is m or less;
m = threshold value for the number of bacteria, the result is considered satisfactory if the number of bacteria in all sample units
does not exceed m;
M = maximum value for the number of bacteria, the result is considered unsatisfactory if the number of bacteria in one or more
sample units is M or more.
2.7 Documentation and records

The Dairy Product (Hygiene) Regulations 1994
require records to be made and kept for inspection in
respect of pasteurized milk.
It is essential that occupiers of milk establishments
arrange for records to be kept in a permanent form
for a period of:
a) at least 2 months in respect of pasteurized
drinking milk or pasteurized milk used for dairy
products which cannot be stored at an ambient
temperature;
b) at least 2 years in respect of pasteurized milk
used in the manufacture of other dairy products.
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Such records relate to the monitoring of the critical

controls mentioned in 2.5, and include:
1) records showing the operation of the flow
diversion device on continuous-flow pasteurizers;
2) charts of recording thermometers installed in
the pasteurizing plant to record the temperature
to which the milk is heated and retained and to
which the milk is cooled;
3) records of the temperature on admission to the
heat treatment establishment and immediately
before pasteurization of any bulk milk which has,
for the purposes of transportation, been heat
treated in another heat treatment establishment;
4) records of the results of plate count tests made
on samples of bulk supplies of heat-treated milk
intended for pasteurization;
5) all microbiological results.
BS 7771:1994
2.8 Pasteurized semi-skimmed and

skimmed milk
For occupiers of dairy establishments who produce
semi-skimmed and skimmed milk attention is
drawn to the need to undertake operations within
the requirements of current legislation (see Table 1
to Table 3).
2.9 Pasteurized milk-based drink or

milk drink
For occupiers of dairy establishments who produce
milk-based drink or milk drink attention is drawn to
the need to be aware of the legal requirements
(see Table 1 to Table 3).
2.10 Health and safety

2.10.1 Health and safety legislation
For pasteurization equipment and work practices
attention is drawn to the Health and Safety at Work
etc. Act 1974 and regulations made under that Act.
These include six sets of regulations which
implement European Directives. Other legislation
includes the Factories Act 1961 and regulations
made under that Act. Of particular relevance are
regulations pertaining to management of health
and safety; workplace health, safety and welfare;
storage, handling and use of chemicals (COSHH);
machinery; electricity and noise. Relevant
legislation is listed in Annex A.
2.10.2 Risk assessment and control
The Management of Health and Safety at Work
Regulations 1992 require employers to carry out
assessments of risks to their employees and
non-employees who may be affected by their work
activity. Employers are then required to make
arrangements for planning, organizing, controlling,
monitoring and reviewing preventative and
protective measures. Significant risks and
arrangements required need to be recorded if more
than five are employed. The record may form part of
the companys health and safety policy statement
which needs to include the organization and
arrangements for implementing the policy.
Competent persons with adequate, theoretical and
practical knowledge should be appointed to assist
the employer in this role.
Employers should assess the risks, list significant

risks in order of priority, identify the standard of
control required and prepare an action plan with
reasonable timescales to achieve compliance.
Arrangements should then be made to maintain
standards.
Recent accident statistics in the food industry show
that fatal accidents are frequently associated with
transport and falls from height. In the milk industry
major accidents are often associated with falls from
height, slips, trips and falls on the level, exposure to
chemicals and hot substances and machinery. These
should therefore be addressed along with any other
significant risks identified in particular workplaces.
Useful guidance is given in the free HSE leaflet
IND (G) 132L Five Steps to Successful Health and
Safety Management. BS 5304 deals with hazards
arising from the use of machinery and methods for
their elimination or reduction. This standard is still
widely used but is gradually being superseded by
European Standards. For example BS EN 294 is
already available. The Dairy Trade Federation also
publishes codes of practice on machinery
safeguarding in relation to bottle fillers,
de/re-craters, conveyors, stackers/de-stackers,
cartoning machines, bottle washers, and crate
handling machinery.
2.11 Advice
Persons in England and Wales who wish to engage
in milk pasteurization on the individual farm
should consult their local Councils Environmental
Health Departments in England and Wales. Advice
may be sought from ADAS, an executive agency of
the Ministry of Agriculture, Fisheries and Food
(MAFF).
In Northern Ireland advice should be sought from
the Department of Agriculture for Northern Ireland,
and in Scotland, from the Scottish Office,
Agriculture and Fisheries Department, the Scottish
Agricultural Colleges and the Local Authority
District Council.
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BS 7771:1994
Table 3 Summary of statutory requirements for milk pasteurization

The health rules for the production and placing on the market of pasteurized milk are laid down in
EC Directive 92/46 of June 1992. Throughout the UK this Directive is implemented by the following
regulations:
The Dairy Products (Hygiene) Regulations 1994
The Dairy Products (Hygiene) (Scotland) Regulations 1994
The Dairy Products (Hygiene) Regulations (Northern Ireland) 1994
Aspect
Registration, licensing,
approvals and
inspections
Description
Premises
Milk establishment
Health mark
Derogations
Labelling
Distribution
Working and storage area
Equipment
Food contact surfaces

Pasteurizer (HTST)
Pasteurizer (Batch)
Hygiene conditions
Bottle washing
Filling of bottles and cartonsa
Premises and equipment
Hazard analysis and critical

control point (HACCP)
Staff
Markings on wholesale
packagesb
Health mark
Other marks
a Derogation may apply for limited production.

b Special dispensations may apply for returnable
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Approvals/requirements
Production holding
MAFF (England and Wales)

Food Authorities (Scotland)
DANI (N. Ireland)
Food Authorities (England and Wales)
Food Authorities (Scotland)
DANI (N. Ireland)
Hygienic construction and standards

Supply of potable water
Pest control programme
Facilities for:
cleaning and disinfection
hand washing and personal hygiene
storage of cleaning materials
storage of packing materials
staff changing rooms
waste water disposal
Corrosion resistant, hygienic construction
and standards.
Fitted with:
automatic temperature controller
flow diversion valve
thermograph with hot milk, cold milk
and events pen
Equipment as approved by the Food
Authority
Mechanical in operation
Filled and sealed automatically
Well maintained
No cross contamination
Cleaned at least daily
Only suitable disinfectants used.
Critical control points:
identified
monitored
checked
recorded
Wear protective clothing
Provide medical certificates when recruited
Undergo approved hygiene training
Applied to all packages
To determine:
nature of heat treatment
date of heat treatment
storage temperature
minimum durability date
glass milk bottles.
BS 7771:1994
Section 3. Design, location and construction of dairy

premises
3.1 General
Enforcing authorities in the United Kingdom may
vary in their interpretation of legal regulations but
the following proposals are given for guidance on
good practice based on experience of milk processing
on the individual farm and in the smaller dairy.
Attention is drawn to dairy legislation covering
dairy premises. A well designed unit is needed to
enable milk to be handled, processed or stored in
such a manner as to prevent risk of contamination.
In order to achieve this, separate units should be
constructed, where practicable, to accommodate the
following.
a) Separate milking house or parlour.
b) Separate raw milk storage area.
c) Separate pasteurizing and milk packaging
room with storage room for clean bottles or single
service containers and milk churns.
d) Separate bottle and milk churn washing room
with storage area for dirty bottles and milk
churns.
e) Separate refrigerated pasteurized milk
storage.
It is not always possible, particularly when utilizing
existing buildings, to provide separate rooms for
items b) and c). Where these operations have to take
place in one room there is nevertheless a need to
separate the work areas used and to give careful
consideration to a suitable and orderly workflow in
order to limit the potential for cross-contamination.
A separate access to each defined work area is also
recommended.
In the design of premises and allocation of space,
consideration should be given to ancillaries without
which it will not be possible to achieve efficiency in
hygiene and operation. These include changing
rooms, sanitary accommodation, refuse storage and
space for services.
3.2 Situation of units at the producer

processors premises
3.2.1 Milking premises
The following should be observed.
a) Milking premises should be sited so as not to
present a risk of contamination and, in
particular, milk should not be handled, processed
or stored where it is liable to become
contaminated or infected. No person should carry
out any process of cooling, pasteurizing, bottling
or packaging milk where the milk would be liable
to contamination arising from any cowshed, byre,
stable, manure heap or otherwise.
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b) Adequate hand washing facilities in the

milking premises should be provided.
3.2.2 Pasteurizing and packaging area
a) Where possible, this should be a separate room
from that used to wash bottles and milk chums
and for their storage prior to washing.
b) The entrance to the pasteurizing and
packaging area should be sited away from the
same yard area in which cows are held before or
after milking or where other animals are kept,
and yard areas should fall away from any access
points to the pasteurizing premises.
c) Direct access to this area by milking personnel
should be prevented.
d) Filling of bottles, single-service containers or
milk churns may take place in this area.
e) Clean bottles, milk churns and single-service
containers sufficient for the immediate needs
may be held in this area prior to filling.
f) Dirty bottles and milk churns (i.e. those
awaiting cleansing) should not be stored in this
area.
g) Suitable handwashing and hand drying
facilities should be provided in this area.
NOTE Non-hand operable taps (e.g. knee or foot operated) and
disposable towels are preferred.
3.2.3 Bottle, milk churn and crate cleansing

area
a) Where possible, the area for cleansing bottles,
milk churns and crates should be a room separate
from the pasteurizing and packaging area.
b) The area should be sited so as not to present a
risk of contamination of bottles and milk churns
after cleansing.
c) Dirty bottles, milk churns, crates and other
equipment awaiting washing may be stored in
this area.
d) If storage of dirty bottles, crates and milk
churns is in an uncovered area then it should be
adjacent to the wash room and not part of the
yard where cows are held or other animals kept.
A raised area is preferable.
3.2.4 Storage rooms
a) After filling, bottles, milk churns and
single-service containers should be kept in a
separate refrigerated store which will keep the
temperature of the milk at 5 C or below.
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BS 7771:1994
b) The refrigerated store should be so constructed

and sited as not to give rise to risk of
contamination of the milk.
c) Adequate dry clean storage for single-service
containers, bottle caps and filter cloths should be
provided.
d) All clean bottles, milk churns and other
containers should be stored in a clean place and
protected from dust, dirt and contamination.
3.3 Situation of units in the small

pasteurizing dairy
3.3.1 Milk reception and raw milk storage
a) Where possible, a separate area for milk
reception and raw milk storage should be
provided.
b) The area for milk reception and raw milk
storage should be sited conveniently to a made-up
roadway suitable for milk delivery by road
tankers.
c) The area should be secure and covered, with
adequate ventilation to remove exhaust fumes
from milk delivery vehicles.
3.3.2 Pasteurizing and packaging area
a) Where possible, the pasteurizing and
packaging areas should be a separate room from
that used to wash bottles and milk churns and for
their storage prior to washing.
b) Filling of bottles, cartons or milk churns may
be done in this area.
c) Clean bottles, milk churns and single-service
containers sufficient for the immediate needs
may be held in this area prior to filling.
d) Dirty bottles and milk churns (i.e. those
awaiting cleansing) should not be stored in this
area.
e) A wash-hand basin complete with suitable
drainage, hot and cold water, soap, towel and
nail-brush should be provided in the packaging
and pasteurizing area.
3.3.3 Bottle, milk churn and crate cleansing
area
a) Where possible, the area for cleansing bottles,
milk churns and crates should be a room separate
from the pasteurizing and packaging area.
b) The cleansing area should be sited so as not to
give rise to risk of contamination of bottles and
milk churns after cleansing.
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c) Dirty bottles, milk churns, crates and other

equipment awaiting washing may be stored in
this area.
d) If storage of dirty bottles, crates and milk
churns is in an uncovered area, then it should be
adjacent to the wash room. A raised area is
preferable.
3.3.4 Storage rooms
a) Pasteurized milk should be kept in bottles,
milk churns, or single-service containers in a
separate refrigerated store which will keep the
temperature of the milk at 5 C or below.
b) The refrigerated store should be so constructed
and sited as not to give rise to risk of
contamination of the milk.
c) Adequate dry, clean storage should be provided
for single-service containers, bottle caps and
filter cloths before use.
d) All clean bottles, milk churns and other
containers should be stored in a clean place and
protected from dust, dirt and contamination.
3.4 General constructional

recommendations
3.4.1 Floors
Floor finishes should be non-slip, heat-resistant,
non-absorbent, robust, easily cleaned and resistant
to acids, alkalis and hot substances.
A well laid quarry tile floor will meet most of these
recommendations. Blue engineering bricks on edge
give a very hard-wearing floor finish. Similarly a
properly laid granolithic concrete floor will be
satisfactory.
Floors should be provided with a minimum fall
of 1 in 60 to a properly trapped drainage system. A
coving to the walls should be provided during
construction.
3.4.2 Walls
Walls should be finished with a smooth, impervious
and washable surface, free from any ornamental or
other unnecessary projection and present a clean
and hygienic appearance. Where possible, service
pipes and conduits should be sunk into walls or fixed
well clear of wall surfaces to facilitate cleaning.
Walls should be well insulated, preferably including
a vapour barrier to avoid condensation and deter
infestation.
3.4.3 Ceilings
Ceilings or roofings should be non-absorbent,
finished to a smooth surface and capable of easy
cleaning.
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BS 7771:1994
Premises should have the best possible lighting

without glare. This should be in the form of
ceiling-mounted fluorescent lights giving an
illumination of at least 300 lx, which should be
increased to 500 lx at specific critical areas,
e.g. filling and inspection. The fittings should be of
plastics or of glass, covered with a plastics shield so
as to prevent fragments of glass entering milk and
milk products.
Windows should preferably be of the hopper type

with inward opening lights. Ideally all windows
should have fly screens fitted to the outside which
should be removable for cleaning purposes and the
sills should be sloping.
All doors should be flush finished on the interior
side, capable of easy cleaning and should be
protected on both sides by non-corroding metal kick
plates to prevent damage which may provide access
for rodents.
3.4.5 Ventilation
3.4.7 Services
The ventilation system should be designed with the

following in mind.
a) The air should be maintained at a temperature
and humidity which will prevent condensation as
far as practicable and assist in keeping milk
rooms cool in summer.
b) Dust, dirt, insects and vermin should be
excluded, particularly from clean areas.
The ventilation requirements will depend on the
purpose for which the room is used but in any room
some degree of mechanical ventilation is desirable.
Particular attention should be given to areas where
steam occurs.
Intake points and the direction of the air flow should
be planned to avoid risk of contamination of milk by
dust, external fumes, etc.
Canopies, if used, should be of the open-tent type
and preferably constructed of polished alloy.
Ventilation ducts inside premises should be fitted
flush with the walls or ceiling or positioned to allow
effective cleaning. Duct inlets should be proofed
against insects and not sited near dusty places.
Services should be installed using suitable piping,

lagging and conduits to facilitate cleaning and
maintenance. Service lines should be positioned to
minimize potential contamination to the product
and minimize hazards in the workplace.
3.4.4 Lighting
3.4.6 Joinery, doors and windows

All internal joinery work should be of simple design
and finished to a high standard of workmanship. A
high gloss surface is required. Unplasticized
polyvinyl chloride (UPVC) surfaces are preferred for
doors, windows, etc.
12
3.4.8 Water supply

Considerable quantities of hot and cold water are
needed. If cold water storage is required the tanks
should be kept covered and protected from extremes
in temperature and from vermin. An overflow
should be piped to discharge outside the building
and in such a manner that any discharge is readily
seen.
The water used in the pasteurizing premises should
be clean water (see 1.3.7). The water should be
microbiologically tested at least twice a year and
especially following cleaning and disinfection of
water storage tanks.
In cases where the total water hardness
exceeds 150 p.p.m. (CaCO3) (see BS 2690-109:1984)
an ion exchange water softener is recommended for
all water where heat treatment, cleaning or rinsing
is involved.
Storage tanks of adequate capacity should be
provided to ensure at least one days supply in case
of supply failure. The tanks and contents should be
inspected at frequent intervals and emptied,
cleaned and disinfected as necessary and at least
once per year.
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BS 7771:1994
Section 4. Components and functions of equipment

used for milk pasteurization on farms and in small
dairies
4.1 Holder (batch) pasteurization
4.1.3 Sequence of operations
4.1.1 General
Milk is admitted to the disinfected pasteurizer

vessel and heated by hot water in the jacket. The
milk is thoroughly but slowly mixed by the agitator
during heating and subsequent operations.
The temperature of the milk is held between 62.8 C
and 65.6 C for a minimum of 30 min before cooling
is commenced either in the vessel or externally.
The pasteurized milk should be cooled to a
temperature not higher than 5 C.
The holder (batch) method for the pasteurization of

milk is permitted. It is a practical alternative to
continuous flow HTST pasteurization only where
small quantities of milk, e.g. up to 1 000 l per day,
are being processed. There may be circumstances in
addition to those of scale where this process has
advantages.
The process consists of heating milk to
between 62.8 C and 65.6 C and retaining it
between these temperatures for at least 30 min.
4.1.2 Basic components of a batch pasteurizer
for milk
4.1.2.1 A vessel of stainless steel is needed within
which the milk is heated to a temperature within
the legally permitted range, maintained at that
temperature as required and subsequently cooled.
The vessel should incorporate an insulated outer
jacket through which the necessary heating and
cooling media can flow.
The heating medium may be either steam at
atmospheric or low pressure or water heated by
steam, electric or gas heating devices. The cooling
medium may be either mains water, chilled water or
a mixture.
The heating and cooling media can be applied to the
outer surface of the vessel either by being passed
continuously through the jacket or by spraying on to
it. Additional cooling after treatment may be
effected by passing the treated milk through a plate
heat exchanger.
4.1.2.2 An agitator, usually fitted vertically and
which rotates continuously during pasteurization, is
necessary to give rapid and uniform heating of the
milk. To avoid butter fat damage, slow speed large
diameter paddles are used.
4.1.2.3 Thermometers should be fitted to indicate
the temperature of the heating medium in the jacket
and the milk in the vessel.
4.1.2.4 A recording thermometer is recommended
for evidence of correct pasteurization and associated
cooling temperatures.
4.1.2.5 A temperature control device is needed
which automatically regulates the heating of the
milk to pasteurization temperatures and the
subsequent retention at these temperatures for the
holding period and cooling. This device is essential
for legal reasons and should be fitted in such a way
as to ensure consistent safe operations.
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4.2 HTST (continuous) pasteurization

4.2.1 General
Heating and cooling duties according to the legal
regulations for pasteurized milk are carried out
continuously in plate heat exchangers.
Groups of high grade stainless steel plates resistant
to the corrosive effects of coolants and chemical
disinfecting agents are clamped vertically in a
frame between a fixed head and a movable follower
which allows the plates to be slackened or removed
for inspection, etc.
The plates are separated by gaskets of synthetic
rubber which are securely fixed in grooves. The
gaskets form seals at the outer edges of the plates
and around two of the four ports in each plate so
that the milk and the heating or cooling water are
distributed across opposite sides of the plate. The
plates are grouped in sections for heating, cooling
and regeneration (heat recovery where heat is
transferred from the hot pasteurized milk to the
cold raw milk). Connector grids provide inlet and
outer ports for the various liquids and separate one
section from the next.
Gaskets are designed to give a double seal between
the liquid streams and make intermixing impossible
between milk and water, or between pasteurized
and unpasteurized milk.
The interspace, or gap, between seals is vented to
atmosphere so that in the unlikely event of gasket
failure, leakage is to the outside and a visual
indication of the fault is produced.
4.2.2 Components of HTST plants
4.2.2.1 The normal components of the milk
pasteurization installation are shown in Figure 1
and comprise the items listed in 4.2.2.2 to 4.2.2.9.
4.2.2.2 The plate heat exchanger (see Figure 2)
comprises regenerative, heating and cooling
sections, of a capacity chosen to suit the daily
processing requirements. Plate heat exchangers for
the pasteurization of milk vary in capacity from
around 225 l/h to around 50 000 l/h.
13
BS 7771:1994
4.2.2.3 A balance tank (see Figure 3), provides a

constant head of milk to feed the milk pump, and
receives any milk rejected during diversion. It can
also be used as the header tank for the circulation of
solutions during cleaning in place. The level is
maintained by a float-operated valve which provides
shut-off against the milk supply. All interior and
exterior surfaces should be polished and
crevice-free.
NOTE A balance tank may not always be fitted to certain
models of small heat exchangers.
4.2.2.4 A centrifugal milk pump should be

constructed of stainless steel and to a design which
will ensure sanitary conditions. The pump passes
milk, cleaning liquids, disinfecting hot water, or
rinse waters through the system as appropriate.
4.2.2.5 A flow control unit (see Figure 4) regulates
the flow of milk to the plate heat exchanger,
irrespective of fluctuations in pressure or head on
either suction or delivery side. It thus performs the
essential function, where a centrifugal pump is
used, of ensuring a constant rate of milk and
eliminating fluctuations which would cause
variations in holding time and possibly in
temperature.
Milk enters at the inlet, passes through a strainer to
the shaped ports in the shell and continues upwards
past the control disc. If the flow increases, the disc
is lifted and the plunger rises to reduce the area of
the ports and so restrict the flow.
A specified rate of flow can thus be maintained with
any particular control disc. Should a different rate
be required the control plunger, with its spindle and
disc, can be removed and a different one substituted.
In some simple small installations a preset
restrictor or orifice plate may be used to control the
amount of milk passing through the heat exchanger.
In these circumstances, especially if no balance tank
is fitted to reduce the variation in flow rate, there is
a need to calculate the throughput in relation to the
designed maximum flow rate.
Phosphatase test failures of skimmed milk but not
of whole milk can result if preheated milk is passed
through a cream separator and back to the
pasteurizer in the absence of adequate flow control
mechanism. While operating under these conditions
the flow controller should be checked to see that it is
in position and a test of the holding time and
temperature should be carried out.
4.2.2.6 A hot water set (see Figure 5 a) and
Figure 5 b) is heated and circulates the water
through the plate heat exchanger to raise the milk
to pasteurization temperature.
14
The water circulating pump is normally located

immediately below on the floor. This compact and
simple arrangement keeps pipelines to a minimum,
thus reducing heat loss. The small amount of water
in circulation ensures a rapid response to changes in
temperature.
Steam injection is controlled by a diaphragm valve
operated via a temperature controller in the panel.
This is actuated by a resistance thermometer in the
mixing vessel. Variations in the water temperature
produce an immediate response in the diaphragm
valve, and consequently in the amount of steam
injected. The water temperature is thus maintained
within very narrow limits.
The steam line is provided with the necessary
reducing and relief valves, and gauges.
Electricity may be used instead of steam to heat the
water required for pasteurization. In this case
immersion heaters, adequate for the pasteurization
rate, are positioned in the tank of the hot water set.
In one design of plant the closed circuit for
electrically-heated hot water circulation includes
the cell in which the milk is held for a minimum
of 15 s at pasteurization temperature.
Vacuum steam heating is an alternative to hot
water as a means of heating the milk.
4.2.2.7 A filter or clarifier is supplied either as a
free-standing or plant-mounted component
depending upon the type of installation.
Where there are two filter chambers, cloths may be
exchanged without interrupting the processing run.
Each chamber contains a tube-shaped filter cloth
supported on a double cylinder of perforated steel
which is easily accessible.
4.2.2.8 A flow diversion valve (FDV) (see Figure 6 a)
and Figure 6 b) and thermograph (see Figure 7) are
needed. The flow diversion valve assembly and the
thermograph together should provide a complete
recording and safeguarding system. The
thermograph, situated in the control panel, gives an
automatic and permanent record of every operation
of the plant from sterilization at start-up to final
detergent circulation. It records not only
temperatures but also every interruption of the
normal run such as a diversion.
The thermograph is operated by a resistance
thermometer located in the milk stream after the
holder. The flow diversion valve assembly is
automatically actuated if the temperature of milk
falls below the preset level. Response is virtually
instantaneous and guarantees that no
unpasteurized milk goes forward.
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BS 7771:1994
For cleaning purposes, and during start-up or

shut-down, the plant is fitted with a manual
override to avoid energizing the flow diversion
valve. It is most important, however, that the
machine is in automatic mode with the safeguards
on while milk is being pasteurized. Regulations
stipulate that thermographs are fitted with a
safeguard event pen which records the position of
the auto/manual switch throughout the operating
cycle of the plant.
Consisting of either a pair of standard on/off
operated valves, or, for specified plants, a single
changeover valve, the flow diversion valve assembly
uses direct air or electrically operated solenoid for
forward flow and spring pressure for diversion, so
that any failure of air or electricity moves the valve
into the diverted position. Diverted milk is bypassed
to the balance tank for recirculation until the correct
pasteurization temperature is restored.
A green light on the control panel indicates that all
is in order, while on a diversion a red light shows
and an alarm sounds.
4.2.2.9 A holding time device is a means of ensuring
that the legal minimum time of exposure to the
pasteurization temperature is achieved. Holding is
most commonly achieved by means of external
holding tubes which ensure that the milk will be
held at pasteurization temperature for a minimum
of 15 s before passing to the first stage of cooling.
4.2.3 Sequence of operations
Raw milk flows from the storage or receiving tank to
the balance tank in which a constant level is
maintained by a float valve.
The milk is pumped at the rate regulated by the flow
controller (or positive pump) to the regenerative
section of the plate heat exchanger. In this section
the raw milk is pre-heated by the pasteurized milk
leaving the holder section, the returning
pasteurized milk being itself partly cooled. The
pre-heated milk passes to the filter then to the
heating section where the temperature is raised to
just above the legal minimum temperature by the
circulation of hot water. Pasteurizing temperature
and diversion are recorded continuously during
operation.
The milk at the pasteurization temperature flows
through the holding tubes and should the flow
diversion assembly and temperature controller
sense that the milk leaving the holding section has
fallen below the minimum pasteurization
temperature it is automatically diverted back to the
balance tank.
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After the holding period of not less than 15 s the

pasteurized milk returns to the plate heat
exchanger for cooling by regeneration, cold water,
and finally by chilled water or other coolant. Cooling
by regeneration results in the milk being reduced in
temperature to around 9 C to 12 C depending on
the type of plant and other factors including the
temperature of the raw milk.
The additional cooling should reduce the
temperature of the pasteurized milk to
between 3.5 C and 5 C.
The temperature of the pasteurized milk is recorded
before it passes to the storage tank and/or
packaging equipment.
4.3 Continuous flow shell and tube

heat exchangers
This type of heat exchanger consists of two
concentric tubes in which the liquid to be heated or
cooled flows through the inner tube and the
heating/cooling medium flows continuously in the
opposite direction through the annular space
between the inner and outer tubes.
In developments of this type of heat exchanger,
infra-red radiation has been used commercially for
small-scale pasteurization. The infra-red radiation
is generated by electrically-heated elements.
In one type of plant the elements are coiled within a
quartz tube with the milk flowing through the
annulus between the tubes, while in another
commercial type of plant the elements are coiled
round the quartz tube through which the milk flows.
In plants of this type the cold milk is pumped to the
regeneration section where it is heated by the
exchange of heat from the hot milk passing in the
opposite direction. The partly warmed milk then
passes across the infra-red radiation elements
where in a few seconds it reaches the pasteurization
temperature of 72 C and is held at that
temperature for the minimum holding period of 15 s
in a series of holding tubes, before preliminary
cooling in the regeneration section and final cooling
by chilled water in the final bank of tubes. Two
solenoid-operated valves are fitted, one at the end of
the holding section, and the other at the diversion
point. Both operate if the pasteurization
temperature is not obtained; one opens the
diversion pipe taking the under-heated milk for
recirculation. The second solenoid-operated valve
shuts off the flow of the milk to the regenerative
cooling section.
15
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Licensed Copy: Oxford Brookes ATHENS, Oxford Brookes University, 27/07/2009
BS 7771:1994
16
Figure 1 Components of a continuous flow HTST milk pasteurization system
BS 7771:1994
Figure 2 General arrangement of a plate heat exchanger
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Figure 3 Balance tank of HTST pasteurizer
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Figure 4 Example of a HTST pasteurizer flow control unit
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BS 7771:1994
Figure 5 Components of a hot water set a) electrically heated
20
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Figure 5 Components of a hot water set b) Steam heated (concluded)
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22
Figure 6 Pneumatic operated flow diversion valve
BS 7771:1994
Key
1. Start up. Plant is switched on at 0600. Control switch is turned to clean or manual position.
2. Disinfection. This plant has been disinfected prior to use with a 20 min circulation of COLD water containing 50 mg/l of
available chlorine, discharged to waste before applying heat. Where steam is available HOT disinfection of the whole plant is
preferred such that the hot pen records at least 80 C for 20 min.
3. Normal running. Plant reaches pasteurizing temperature of 72 C at 0700. Control switch is turned to auto or run position.
Safeguards (event) pen moves to the middle position. Raw milk is admitted to the plant. Pasteurized milk is cooled to 5 C.
4. Diversion. At 0845 the temperature of the milk falls below 72 C resulting in the milk being diverted. Diversion lasts for 30
min. The safeguards pen records this event in the lower position.
NOTE 1 Flow diversion would normally last for a shorter period. The time of 30 min is used for diagrammatic purposes.
NOTE 2 It is recommended that the flow diversion value is tested daily for correct operation in the early stages of the process
run.
5. Normal running. At 0915 the temperature returns to 72 C and the plant resumes its normal running for another 1 h. The
safeguards pen returns to the middle position.
6. Detergent circulation. At 1 100 pasteurization ceases, the plant is shut off and the filter and flow controller removed. Control
switch is turned to clean or manual. The safeguards pen moves to the upper position. At 1 108 detergent circulation starts
and is maintained at 86 C for 40 min. Control switch is turned to manual/divert for 10 min to clean the FDV.
7. Shut down. At 1 150 the plant is rinsed out and switched off.
Figure 7 Illustration of a thermograph chart
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BS 7771:1994
4.4 Choice of pasteurizing plant,

commissioning, pre-production tests
and preliminaries
4.4.1 Choice of plant
When planning pasteurizing operations a decision
should be made on the system which is most
suitable to the intended scale of operations and
other factors.
Advice should be sought on all aspects of milk
pasteurization equipment and installation and only
those types of plant which have been approved by
enforcement authorities should be considered.
Visits should be made to a number of installations
with a proven record of effective pasteurization over
a substantial period of time.
Pasteurization plant should only be purchased from
reputable equipment suppliers. The purchaser
should satisfy himself as to the suppliers warranty
of the ability of the equipment with regard to
current legislation covering the production of a safe
pasteurized milk supply as well as installation,
servicing, fault finding and maintenance provision.
4.4.2 Commissioning
4.4.2.1 General
Competent engineers and electricians should set the
plant up correctly. The operator should be given an
instruction booklet which clearly lays out the
method of starting up, shutting down, cleaning and
disinfecting the plant. Practical training should be
provided by the installer. Any subsequent staff
engaged in the operation of the plant should be
given full training and should be conversant with
operational instructions.
To ensure efficient operation and management the
operator should be aware and familiar with the
pasteurizer instrumentation requirements, as
follows.
a) Any thermometer, dial or digital display of
temperature should be clearly visible and
accessible to the operator.
b) An accurate reference thermometer should be
available on site. Such thermometers may be
mercury-in-glass, alcohol-in-glass or digital
electronic and should have clear graduations
at least every 0.2 C.
c) All pasteurizers should be fitted with a
thermometer having spaced graduations at least
every 2 C, so as to indicate the temperature to
which the milk is heated (hot indicating
thermometer).
d) All pasteurizers should be fitted with a
thermometer so as to indicate the temperature to
which the milk is cooled (cold indicating
thermometer).
24
e) All HTST pasteurizers should be fitted with an

automatic and continuous recording and
indicating device (thermograph) to provide
permanent records of the following:
Temperature during
pasteurization
(Hot pen)
Temperature upon final cooling
(Cold pen)
Flow divert activity
(Event pen)
Mode of operation: manual or automatic

Milk flow diversion
Plant cleaning: temperature and
time
(Hot pen)
Tracings obtained from the hot pen and event

pen should operate within the same time arc.
The recording charts should be marked with
graduations at least every 2 C, adequately
spaced to give clear readings, dated and
preserved.
NOTE
Reference should be made to appropriate legislation.
f) All HTST pasteurizers should be fitted with a

flow diversion valve which is accurately set to
activate should the milk holding temperature fall
below 71.7 C. The position of this valve should
ensure all milk is diverted when activated.
g) All HTST pasteurizers fed by a centrifugal
pump should be fitted with a flow control valve or
restrictor limiting the milk flow rate within the
designed plant capacity, regardless of any
changes of pressure before or after the point
where it is fitted.
Regular checks and calibration of all
instrumentation referred to in a) to g) are essential
to produce milk of good quality. Attention is drawn
to the regulations covering checking and
calibration. (See section 5.)
4.4.2.2 Commissioning checks
The following checks should be made.
a) When the plant is run, even on water, the time
used on forward flow, e.g. 1 h, or part thereof,
should produce the volume per hour or part
thereof to design specification. Flow can be
measured easily by using calibrated milk churns.
b) It is important to know the exact capacity of
the plant, first to calculate the detergent
concentration, and secondly to ensure that the
correct quantity of water or milk is flushed out
when starting up or shutting down the plant. The
quantity of fluid left in the balance tank should be
subtracted from the manufacturers capacity
figure to get a more exact figure for flush out at
the beginning or end of the operation.
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c) The accuracy of the chart readings should be

checked against the indicating thermometers at
each process run.
d) The plant indicating thermometer should be
calibrated regularly against either:
1) a mercury-in-glass thermometer conforming
to BS 593:1989 Series A, B or F and should
hold a current traceable NAMAS Certificate1).
or:
2) other thermometers, e.g. electronic, having
at least an equivalent accuracy.
During the trials a number of measurements should
be made.
i) Measurement of the flow rate of the milk during
the test.
ii) Measurement of the minimum holding time by
a recognized test method.
iii) Measurement of the pressure of the milk at
different points in the installation in order to be
able to calculate the differences in pressure
between raw and pasteurized milk.
iv) Recording of the length of the complete plate
pack in order to judge the changes which take
place during the service life of the pasteurizing
installation.
Samples should be taken aseptically of the raw milk
and the heat-treated milk and these should be
tested for comparison purposes. Table 2 gives a
summary of the statutory limits in the appropriate
dairy legislation.
The heat treated milk sample should be taken at the
end of the cooling section of the pasteurizer if
possible. If this is not possible, the sample should be
taken from the discharge point.
Attention is drawn to the statutory limits
concerning the minimum holding time and the
pasteurization temperature.
From the results of comparative phosphatase tests
the safe operating temperature of the pasteurizer
can be determined. To provide a safety margin
above the phosphatase limit the temperature
settings may be increased by 1 C and 0.5 C
respectively for the operating temperature and flow
divert system.
In the case of non-homogenized milk the
temperature margin above the phosphatase limit
should be not greater than necessary, to prevent
damage to the cream line formation.
As part of the pre-production tests, an inspection of

the operating instructions should be carried out.
The written instructions and guidance provided by
the installer should clearly indicate how the
pasteurizer operator should act at the start of
pasteurization, during the operation, in the event of
a flow diversion or stop of flow occurring, as well as
during the shut-down, cleaning and disinfection of
the plant. The written instructions and guidance
should also cover the recording of the essential
temperatures and simple inspection and
maintenance procedures.
The determined pasteurization temperature and
flow diversion temperature should also be included
in the operating instructions.
Sale of pasteurized milk should only be started
when the dairyman, installer and the enforcement
authority officer are satisfied that the installation is
operating satisfactorily (considering statutory
requirements and production of a high quality
product).
At commissioning, the accuracy of the readings of
the pasteurization thermometer and the cooled milk
thermometer should be checked by comparison with
a calibrated glass thermometer sited close to the
plant thermometer that is being inspected and
checked.
4.4.2.3 Follow-up checks
The installing dairy engineer should check all
instruments after 1 month and then after 6 months
in service as follows.
a) Check that the flow diversion valve opens
at 71.7 C on a rising temperature.
1) NAMAS
certificates are available from the National Measurement Accreditation Service (NAMAS), National Physical
Laboratory, Teddington, Middlesex TW 11 OLW.
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BS 7771:1994
b) Check the accuracy of the thermometer

recording the temperature of the milk leaving the
plant and record it.
c) Re-check the flow diversion valve to see that
the valve closes at 71.7 C on a falling
temperature.
d) Take samples of milk for the phosphatase test
at the beginning, middle and end of a run and
submit them to a competent laboratory for
testing.
Further samples from further consecutive
processing runs may be required by the enforcement
authority.
Samples of milk at the beginning and the end of a
run should be analysed for quality purposes.
A system of maintenance should be drawn up with
the dairy engineer responsible for the installation
(see section 5).
The dairy engineer should be asked to recommend
the necessary spares which should be carried to
make normal repairs. All spares should be kept
clean, dry and free from detergent or oil
contamination.
26
4.4.3 Pre-production tests and warranty

The processor should ensure the installer makes
pre-production tests of a new pasteurization
installation or of an installation which has
undergone major modifications or refurbishment.
The installer should be required to guarantee that
the components of the pasteurization system are in
sound condition. This is particularly important
where some or all of the components have been used
before.
Pre-production tests should only be applied when
inspection and adjustments based on check tests
with water have been satisfactorily completed.
Sufficient bulk raw milk should be available for a
minimum of six test runs of the pasteurization
installation.
The raw milk bacteriological standard is given in
the relevant Dairy Products (Hygiene)
Regulations 1994.
The pre-production tests are performed with milk at
the full nominal processing capacity of the
installation with a minimum of six heat treatment
temperature adjustments ranging from some
degrees above to some degrees below the expected
phosphatase-negative temperature.
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Section 5. Pre-processing operations (reception,

storage) and milk handling before pasteurization
5.1 General
5.3 Bulk milk supplies
Milk as drawn from the healthy cow can be expected

to contain relatively few bacteria.
At the time of milking and during subsequent
handling on the farm, bulk collection and delivery to
the dairy and while stored at the dairy prior to
pasteurization, raw milk becomes contaminated
with micro-organisms dependent upon the
standards of hygiene which have been applied in
cleaning and disinfecting the contact surfaces with
which the milk comes into contact.
Further factors which influence the bacterial
numbers prior to pasteurization are the length of
time from production until processing and the
temperature of milk until it is pasteurized.
The hygienic quality schemes operated by milk
buyers in the United Kingdom are intended to
encourage milk producers to supply raw milk of a
good hygienic quality covered by legal regulations
and meeting market requirements.
Specifications agreed by the dairy industry for
tanker loads of raw milk are intended to assure the
dairy establishment that the quality of the raw milk
received for processing is satisfactory for production
of a high quality pasteurized milk.
Occupiers of dairy establishments should test bulk

supplies of raw milk in accordance with a systematic
and efficient quality control programme.
For dairy establishments of any size the
temperature of raw milk on reception is vital
information and all tanker loads should be tested.
The milk producer has to cool the milk immediately
after milking and maintain it at 8 C or less for daily
collection or 6 C or less if not collected daily.
Upon acceptance at a dairy establishment (unless
heat treated within 4 h) milk should be cooled
to 6 C or lower and maintained at that temperature
until heat treated.
5.2 Raw milk quality

An important part of current legislation is that
concerning the prescribed bacteriological quality of
milk intended for pasteurization. The statutory
requirement throughout the United Kingdom is
that in the 2 months prior to pasteurization of an
individual farm milk supply, or of a bulk supply of
milk, a minimum of two plate count tests will have
been made each month on samples of the individual
farm supply and of the farm supplies making up the
bulk supply and the geometric average of the plate
counts will not have exceeded 100 000 bacteria per
millilitre.
Records of the results of plate count tests made by a
competent laboratory on the samples of milk from
the individual producers milk supply have to be
retained for 3 months for inspection by the local
authority or other enforcement authority.
In the case of the bulk raw milk delivered to a dairy
establishment the vendor of such milk should
provide a warranty of the quality based upon sound
hygienic quality schemes. If an individual farm
supply, which is a normal component of a bulk
supply intended for pasteurization, fails the
prescribed quality standard, the offending supply
should be diverted from use for pasteurization until
the quality is restored.
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5.4 Protecting milk quality

5.4.1 General
Where raw milk is not treated within 36 h of
acceptance, the legal requirement is that a further
test should be carried out on such milk before it is
heat treated. If it is found that the plate count of
that milk at 30 C exceeds 300 000 per millilitre,
then such milk cannot be used for the production of
heat-treated milk. The holding of raw milk is
unlikely to be a normal practice in small dairies but
might occur in unusual circumstances.
During storage there is multiplication of some of the
bacteria present, the rate of growth being affected
by time/temperature conditions. The bacterial count
of raw milk prior to pasteurization is determined by
the number of bacteria in the original milk at the
farm, the additional bacteria gaining access to the
milk from the surfaces of the refrigerated farm tank,
the collection tanker and ancillaries and the storage
tank at the dairy.
The recommendations in 5.4.2 to 5.4.3 are made for
the pre-pasteurization operations to limit
deterioration of raw milk.
5.4.2 Producer retailers, producer processors
All storage vessels including the refrigerated farm
tank should have been properly cleaned and
disinfected as described in BS 5305:1984 before use.
The appearance, smell and taste of milk produced
on the farm and any additional supplies purchased
should be checked.
Checks should be made to ensure that the milk is
properly cooled after milking and held below 5 C
until pasteurization.
The milk should be thoroughly mixed before
pasteurization so that the fat content of the milk is
uniform throughout the run.
All equipment used for milk handling and storage
should be disinfected immediately before use.
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BS 7771:1994
All equipment should be cleaned immediately after

use so that milk residues are not allowed to build up
on the plant surfaces.
5.4.3 Dairy establishments
The milk should be inspected prior to acceptance
and off-loading, in accordance with industry
standards. As a minimum, the following tests on all
tanker loads should be undertaken and the delivery
of milk accepted only if the results are satisfactory.
a) Check that the appearance, and smell and
taste (see note) are typical of pure new milk;
sweet, clean and marketable.
NOTE To avoid the risk of infection, it is advisable that raw
milk is not tasted as part of a reception procedure for milk
supplies. Milk should be tasted only after it has been
laboratory-pasteurized and cooled.
b) Check the temperature of the milk and follow

the procedures agreed with the appropriate milk
supplier if the temperatures are unsatisfactory.
Since few storage tanks have refrigeration, the
milk needs to be at low temperature before filling
in to the tank.
28
Provided the milk is of acceptable quality, the

supply should be pumped to a storage tank which
has been thoroughly cleaned and disinfected by the
procedures described (see section 11). If the tank
has been disinfected by heat it is essential that the
tank has been vented and cooled before use.
The milk should be pasteurized as soon as possible
after reception keeping overnight stocks of raw milk
to the minimum and at a temperature not
exceeding 5 C.
The milk in the storage tank should be mixed
thoroughly before pasteurization to ensure uniform
fat levels in the milk throughout the run.
Pre cooling milk immediately before pasteurization
to a set temperature (e.g. 2 C to 3 C) helps reduce
the temperature of the final product and ensures
process consistency.
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Section 6. Operation of pasteurizing plant

6.1 Operating procedures
6.1.2.2 Start-up
6.1.1 General
Prior to disinfection (see section 11), assemble the

plant completely, including connecting pipework.
Thermometers and thermographs should be in
position.
Operating methods vary according to the type of

plant, its design and the degree of automation of its
control systems. Instruction manuals of plant
manufacturers are generally comprehensive and
details from them need to be incorporated into plant
procedures.
Typical operational procedures for the two main
types of plant, the batch type and the continuous
HTST type, are outlined in 6.1.2 and 6.1.3, but
actual procedures will vary, reflecting variations in
detail for specific plants from different
manufacturers.
Factors which require to be taken into account in
order to ensure the efficient operation of a plant are:
a) an adequate supply of water, steam and other
services;
b) suitable accuracy and adequate reliability of
control equipment and instrumentation;
c) adequate maintenance of electrical and
mechanical equipment;
d) adequate training and supervision of operating
personnel;
e) correct cleaning, disinfecting and processing
procedures;
f) laboratory control checks.
In addition to ensuring efficient plant operation
attention is drawn to the statutory requirements
relevant to pasteurization plants including that:
1) the temperature programmes for plants, either
batch or continuous types, and the final
temperature to which the milk is cooled after heat
treatment are met and that records of such
temperatures are kept;
2) provision is made for diverting the flow
automatically of any milk in a continuous plant
which has not reached the pasteurization
temperature and that a record of the operation of
the diversion flow valve is kept;
3) tests are applied to the final pasteurized
product to ensure that it has been adequately
heat treated (phosphatase test) and to ensure the
maintenance of plant hygiene and final milk
(microbiological tests).
6.1.2 HTST plant
6.1.2.1 General
The procedures outlined in 6.1.2.2 to 6.1.2.6 apply
to a plate pasteurization plant with a control unit as
illustrated in.
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6.1.2.3 Disinfection
Disinfect the assembled plant using either steam,
hot water or chemical solutions. Where hypochlorite
is used as a disinfectant, it is strongly recommended
that the solution should be circulated cold in order
to minimize corrosive action on the stainless steel
plates. In any event, the temperature of the
hypochlorite solution should not be greater
than 40 C. See item 5) in 8.4.2.3 and note 3
to 11.5.3.2.
6.1.2.4 Processing of milk
6.1.2.4.1 Plant with drainage facilities
After disinfection and rinsing as necessary, stop the
plant and shut down services. Open all vents and
drain plugs, loosen pipe joints at low level and
slacken off the heat exchanger. Loosen filter covers
if necessary. Allow to drain.
When the plant has drained completely, tighten up
all joints, fit the filtercloths and turn one of the
filters to the open position.
Activate the safeguards by setting the auto/manual
switch to auto or the clear/run switch to run and
ensure the direct set pointer is to the required
diversion temperature. Turn on the mains and fill
the hot water set. Turn on the milk supply, the
product and hot water pumps and the cooling water
supply (where fitted turn on the air and/or steam
supplies).
NOTE If brine or propylene glycol is used as coolant, do not turn
it on until after the milk has passed the diversion valve to avoid
danger of freezing.
When the milk starts to discharge, close the drain

and vent plugs.
Turn the set pointer of the product temperature
controller to the required position above the
diversion temperature. Forward flow should occur
when the pen passes the diversion set point and the
alarm will sound. Switch off the alarm or set to
mute.
Check that all heating and cooling temperatures are
correct and that the chart records agree with the
indicating thermometers. Check that any pressure
gauges fitted read normal for the control conditions.
Take a sample of the milk for test purposes.
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BS 7771:1994
6.1.2.4.2 Plant without drainage facilities
6.1.2.6 Shutting down
In small pasteurizing plants in which there are no

drainage facilities, the following procedures should
be used after disinfection and rinsing.
a) Do not stop the plant but with the auto/manual
switch at auto allow the outlet to run to waste
whilst maintaining a supply of additional mains
water to the balance tank.
b) Set the pointer of the temperature control to
the required pasteurization temperature. Fit the
filtercloths (where appropriate) and turn on the
coolant.
c) When the correct pasteurizing temperature has
been established allow the balance tank to run
almost dry and then start the milk supply. After
sufficient time has elapsed for the plant to be
completely free from water, milk is allowed to
enter the pasteurized milk storage tank. This is
done by operating the plant outlet valve.
6.1.2.6.1 General
6.1.2.5 Running
When the temperatures have stabilized and the
milk is flowing freely, check the thermograph
readings against the preset indicating
thermometers for the hot and cold sections.
Each of the indicating thermometers should be
checked regularly against a calibrated reference
thermometer and any corrections recorded on a
label attached to each indicating thermometer. The
temperature at which diversion occurs should be
checked daily during cleaning and disinfecting.
The operator should be familiar with the readings
required and the normal variations to be expected
for all thermometer and pressure gauges
throughout the plant so that a continual check can
be made of operating temperatures. Any deviations
may indicate a fault condition. Statutory
requirements stipulate that records have to be kept
of thermograph charts showing processing
temperatures (see 2.7).
During processing an approximate value of the
holding time can be obtained from the average flow
rate, i.e. the total volume of milk pasteurized
divided by the total running time. The processor
should seek validation, confirming that the plant is
designed to ensure that a minimum 15 s holding
time is achieved at a specified flow rate.
A change which may affect the flow rate is the
choking of filter cloths by debris. Filter cloths should
be changed if the raw milk inlet pressure rises
by 20 kPa above that normal for a clean cloth or at a
frequency dictated by experience.
During any pasteurization run the milk pump
should not be allowed to run dry.
30
It may become necessary to shut down a

pasteurizing plant in normal operations because of
either a shortage of milk supply or lack of storage
capacity for the product or for cleaning.
It may also become necessary to shut down because
of an emergency situation. Factors which may give
rise to emergencies include:
a) failure of supply of services, e.g. complete or
partial failure of water supply, power failure or
coolant supply;
b) breakdown of equipment such as the drive
motor, refrigeration plant, or controllers of
recording instruments or their air supply;
c) blockage of flow controllers, freeze-ups, etc.
The duration of the shut down may be of short
duration (not more than several minutes) or of long
duration (several hours).
It is important in either case that milk in the
holding section of the heat exchanger which has
been underheated be not allowed to pass to the
cooling section.
If the flow of milk is stopped, the heating should be
immediately turned off to avoid burning-on and
when brine or propylene glycol is used as coolant it
should be turned off to avoid freeze-up.
6.1.2.6.2 Shut down of short duration
Proceed as follows.
a) Switch on manual divert to return milk to the
balance tank or raw milk inlet.
b) Turn off the supply of heat to the hot water set
(steam or electricity) and, if possible, fill with cold
water.
c) As soon as the plant is cool, stop the milk and
hot water set pumps.
d) To recommence processing restart the milk
and hot water set pumps and turn on the steam
water and coolant supplies.
6.1.2.6.3 Shut down of long duration
The milk remaining in the plant needs to be flushed
out with clean water. The general procedure for this
is as follows.
a) Turn off the raw milk supply.
b) Allow the balance tank to become almost
empty of milk and then run clean water into it
until the discharge is clear.
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BS 7771:1994
c) Manually turn the outlet valve from the

pasteurizer to allow the water which follows to
run to waste. Alternatively the valve may be
operated automatically using the electrical
conductivity of the outflow to control the
switching.
d) When the last milk has flowed out turn off the
hot water energy supply (unless cleaning is to
commence immediately) and coolant. If brine is
used as coolant, it is essential to drain and rinse
the brine section to avoid corrosion of the plates.
e) Turn the auto/manual switch to manual or
the clean/run switch to clean. Stop the milk and
hot water set pumps as soon as the outlet flow is
clear.
Following the shutdown and before processing of
milk is resumed it is essential that the plant be
cleaned immediately and that it be thoroughly
disinfected immediately preceding any new
processing run. The length of time for which a plant
may be run before it is shut down for routine
cleaning has to be determined from experience but
it is normally at least 5 h.
6.1.2.8 Fault finding in HTST control systems

Manufacturers of pasteurizing plants should
provide procedure charts for fault diagnosis which
should include:
a) symptoms and possible causes;
b) checks to be carried out by the operator;
c) remedial action required.
6.1.3 Holder (batch) plant
6.1.3.1 Start-up
Pre-clean all parts of the plant including connecting
pipework and any associated equipment with which
milk may come into contact. Disinfect the plant
immediately before processing. Drain completely
and rinse as necessary. After drainage, ensure that
all joints and connections are tightened.
6.1.3.2 Processing
6.1.3.2.1 Filling
In the event of power or pump failure, it is

important that the plant be cooled as quickly as
possible to avoid burning on. Mains water from a
hosepipe should be forced through the plant, if
necessary, to remove all residues of milk.
Close the outlet of the pasteurizing vessel and fill

with cold milk to the working level. Preheated milk
may also be used, in which case the surfaces of the
vessel should also be preheated. Contact with raw
milk with surfaces not to be heated such as the
underside of the vessel cover and outlet pipes should
be avoided. Unless the raw milk inlet and outlet
pipes are equipped with means to avoid forward
passage of unpasteurized milk, it is strongly
recommended that the outlet pipe be disconnected.
6.1.2.7 Action on freeze-up
6.1.3.2.2 Heating
When brine or propylene glycol is used as the

coolant, occasional accidental freeze-ups may occur
in the cooling section of the heat exchanger. The
following remedial action should be taken.
a) Turn off the coolant and cooling water if used
to clear the blockage.
b) If carrying out item a) is not effective, stop the
milk pump and turn off the steam supply.
c) Connect the cooler outlet to the balance tank
and drain the brine from the cooling section.
d) Connect a supply of water to the brine drain
and flush until water flows out of the top of the
brine service pipe.
e) Turn on the steam and milk pumps.
f) When the brine section has thawed, allow
water to drain from the brine side and then close
the vents and drainage points.
g) Turn on the brine or propylene glycol and
restart.
Start the agitator and fill the water jacket with hot
water at the required temperature. Open the steam
and hot water inlet valves or switch on the
immersion heaters. When the temperature of the
milk reaches 62.8 C, or shortly before, turn off the
heating (steam or immersion heater) to avoid
overheating.
6.1.2.6.4 Emergency shutdown
BSI 06-1999
6.1.3.2.3 Holding
Maintain the milk at a temperature between 62.8 C
and 65.6 C for 30 min. The temperature throughout
this period should be recorded on the thermograph
(where fitted) which should be checked daily against
a precalibrated indicating thermometer.
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BS 7771:1994
6.1.3.2.4 Cooling
6.2.2.3 Balance tank
At the end of the holding period, cool the milk by

either:
a) passing cold or chilled water through the water
jacket; or
b) discharging the milk to an external cooler. In
this case, as the level in the vessel falls, hot water
should be drained from the water jacket and cold
water admitted to avoid burning on of milk solids.
Reconnect the discharge pipe and open the outlet
valve and allow the milk to flow by gravity or pump
it to the cooler.

a) The inlet valve may stick causing improper
flow of milk.
b) When circulating detergent solution, the
return pipe to the tank should be taken below the
liquid surface to avoid aeration of the solution.
c) Never add powdered detergent direct to the
balance tank, always dissolve the detergent in
water in a plastics or stainless steel bucket.
d) Always keep the balance tank covered.
6.1.3.2.5 End of run

After the milk has been discharged turn off the
agitator and open the pasteurizer. Rinse all surfaces
with first warm and then cold water until the vessel
is cold and the water runs clear. If the plant is to be
reused immediately, drain it completely otherwise it
should be cleaned thoroughly.
6.2 HTST plant operation: practical

aspects of ensuring efficient
pasteurization
6.2.1 Testing and commissioning
Most of the problems with pasteurizers occur at
installation.
The details of tests carried out on commissioning
are given in 4.4.2.
6.2.2 Fault finding
6.2.2.1 General
In any pasteurizing plant the easiest way to locate
faults is to allow the flow of milk through the plant.
The more common faults seen in pasteurizing plants
are summarized in 6.2.2.2 to 6.2.2.12 together with
precautionary measures.
6.2.2.2 Raw milk
The quality of milk should be regularly checked
whether it is produced on the farm where
pasteurization will take place or where it is
delivered by road tanker (see section 5).
32
6.2.2.4 Milk pump

Avoid damage to the milk pump from debris such as
broken glass or other foreign bodies. Damage from
such material may affect flow rates.
6.2.2.5 Flow controller
a) Where screens are fitted around the piston
type of flow controller, ensure they are clean and
sound. Dirty screens reduce flow. Holes in screens
may allow debris through which will clog up the
flow controller.
b) The absence of screens may mean that debris
is carried over onto the heat exchanger plates
leading to build up of scale on the plates and filter
cloth damage.
c) When the flow controller is removed it should
be kept in a safe place in a plastics container to
avoid scratching or other damage. If it is not
replaced, flow will be too fast and lead to
phosphatase failure.
6.2.2.6 Pressure gauge
Where a pressure gauge is fitted it should be
referred to daily; deviations in pressure can indicate
trouble with the pump, flow controller, filter cloth or
build up on the heat exchanger. Remove regularly to
check cleanliness and proper functioning.
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BS 7771:1994
6.2.2.7 Heat exchanger

a) Vents, if fitted, should be open when the plant
is started up. They should be closed when liquid
is coming out of them freely.
b) Running time should not exceed 6 h as long
running times result in milk deposits collecting
on the heating surface.
c) Deposit quickly builds up if the pump is
allowed to run dry when it should be pumping
milk. The heat exchanger is starved of milk, the
flow stops and milk starts burning on the heated
surface.
d) In plate pasteurizers the plates should be
numbered by the manufacturer so that their
position in the pack can be readily identified if
they should be removed for inspection.
e) Plate heat exchanger gaskets should last 4
years to 5 years but their life is shortened by the
following.
1) The excessive use of acid, particularly at
temperatures above 40 C and at
concentrations greater than recommended.
2) Too frequent opening of the plate pack.
3) Incorrect or uneven tightening of the plate
pack. (Before opening the plate pack its overall
length should be measured accurately, noted,
and the plate pack returned to these
dimensions.) The following precautionary
measures should be taken.
i) Running bars and screws should be
lubricated with a smear of petroleum jelly to
ensure the plates and follower can move
freely and evenly.
ii) Replacement gaskets should be fitted by
a competent engineer in accordance with the
suppliers instructions. Metal abrasive,
e.g. steel wool or copper scourer should not
be used to remove debris, scale or stains
from the heat exchanger plates.
f) If the milk stock runs out while waiting for
further supplies the pasteurizer may be run for
several minutes by circulating milk, which
should then be discharged to waste. Alternatively
the plant temperature can be maintained by
circulating hot water. Ensure that the plant is
free of water before recommencing the forward
flow of pasteurized milk (see 6.1.2.4).
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g) Retail milk returned to the dairy should not be

re-processed as it will almost certainly be of poor
bacteriological and chemical quality and may
contain foreign bodies, e.g. glass, which can
damage the milk pump.
h) Build up of deposit in the heat exchanger may
be identified by checking the temperature
difference between that of the hot water and that
of the milk. Normally this difference is about 4 C.
If it is much greater than 6 C, it probably
indicates milk deposit in the heat exchanger
making heat transfer to the milk more difficult
and thus automatically increasing the hot water
temperature in compensation.
i) Over-tightening the plate pack can lead to
reduced flow resulting in loss of creamline and a
shorter life for the gaskets.
6.2.2.8 Flow diversion valve
a) The flow diversion valve (FDV) can leak if it
does not seat properly. Failure of the electrical
or air supply, or worn or defective components
may cause poor seating. The valve seat itself may
be cracked causing a leak.
b) At some stage during circulation cleaning, the
FDV should be opened so that it is cleaned by
circulation. When the FDV is opened there is a
stronger circulation in the hot water section thus
assisting cleaning where it is needed.
c) If the FDV is solenoid operated a spare solenoid
has to be kept as the plant will continually divert
on a failure.
6.2.2.9 Filter section
Filter cloths should be rinsed with clean water after
removal from the plant and washed and disinfected
as described in 11.6. When reassembled in the filter
the cloth should be fitted with the nap or woolly
surface exposed to the milk flow and then rinsed in
clean cold water before being refitted.
6.2.2.10 Instruments: instrument panel
a) The instrument control panel can be made up
in many differing ways but essentially it has one
or more thermographs, a temperature controller
and various plant indicators depending on the
mode of heating or control system adopted.
33
BS 7771:1994
b) If there is only one thermograph it will have a

hot milk and a cold milk pen. A safeguard or
operations pen which shows diversions and the
position of the clean and run switch is also
recommended. On this type of thermograph many
also have a diversion set point which indicates
the temperature of diversion.
c) This diversion set pointer can sometimes be
moved accidentally when taking out the
thermograph chart. This should be set so that it
cannot be altered accidentally to avoid the
possibility of phosphatase test failure.
d) A range of electronic and conventional
expansion type indicating thermometers is
available for on plant installation. Hot milk and
cold milk recording pens on the thermograph are
purely mechanical and are only as good as the
maintenance and checking they receive. They are
only as accurate as their regular comparison with
a known accurate thermometer provides.
e) Statutory requirements stipulate that dated
and signed thermograph records are retained
(see 2.7). Apart from the necessity of keeping
records for public health reasons the daily chart
is a valuable record showing how the plant has
behaved over a period of time.
34
6.2.2.11 Hot water set and associated hot water

pump
The importance of inspection and maintenance of
this item should be appreciated and proper action
taken.
Failure to provide a supply of hot water required for
the heating section may be caused by complete
failure of the hot water pump, partial failure due to
the pump operating in the wrong direction, leakage
from the hot water set, and debris restricting the
steam injection nozzle (if fitted).
6.2.2.12 Pipelines
a) The pipelines associated with the plant will get
adequate circulation in routine cleaning. Where
there is a change in the diameter of a pipeline,
there will be improper circulation at this point.
Such junctions should be regularly checked to
ensure there is no build-up of deposit.
b) Where pipelines other than those of the
pasteurizer are involved in circulation the extra
volume of liquid involved should be allowed for, in
calculating detergent strength or in allowing for
the flush out of water or of milk. Such additional
pipework however may impair cleaning and
should be avoided where possible.
c) All pipelines used to convey milk should be
arranged with a slight fall back to the pasteurizer
in order to complete drainage after cleaning
operations.
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BS 7771:1994
Section 7. Milk packaging, storage and handling

7.1 Milk packaging
7.1.1 General
The containers into which pasteurized milk is filled
fall into three broad categories, namely, cans, glass
bottles, and single-service containers. From the
point of view of contamination, cans and glass
bottles are the most hazardous, and they should be
cleaned effectively and disinfected before re-use.
Packaging operations range in type from low
throughput manually-operated fillers which may be
used in small-scale milk processing operations to
large throughput mechanized and automated bottle
filling and single-service container packaging lines.
Provided the machine has been efficiently cleaned
and disinfected there should be little contamination
during filling but the packaging stage remains a
cause of failure of statutory quality tests and
product spoilage.
7.1.2 Churns
Pasteurized milk filled from a balance tank into
churns is usually drawn through a filling valve
fitted with an anti-drip device. This filling head
requires thorough cleaning and disinfection at least
once a day. Intermittent use should be avoided if
possible, but if this cannot be arranged, churns
should be filled in batches, to allow for the head to
be removed for cleaning and disinfection in the
intervals between batches (see section 11). When
not in use the filling head should be kept covered to
guard against contamination.
7.1.3 Glass bottles
Bottle filling machines used in the dairy industry
range from the low throughput hand-operated and
simple mechanical fillers to highly mechanized
units capable of filling several hundred bottles per
minute. Capping units have been developed to suit
the needs of the filler and provide a tight crimped
seal to the milk bottle. Much thought has been
directed to the problems of cleaning and
disinfecting. In modern high capacity units the
filling machine can be cleaned and disinfected by
cleaning-in-place methods. Others with older and/or
small throughput equipment may have to be
dismantled for manual cleaning, then reassembled
for disinfection (see section 11). Irrespective of the
system used, special attention should be given to the
following:
a) filling valve assemblies;
b) rubber seals for the bowl and inspection lid;
c) vacuum tube;
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d) vacuum extraction fan;

e) float valve assembly;
f) cap crimping heads.
The cap feeding device requires particular
attention, not only at the end of a run but at
frequent intervals during the day, owing to the fact
that it may be splashed with milk or come into
contact with milk on cap release failure.
Aluminium foil should be stored under clean, dry
conditions; reels should be handled hygienically.
Unused foil should be removed from the machine at
the end of the days run and put into clean dry
storage until the next run.
7.1.4 Single-service containers
Single-service containers may be formed in situ on
the filling unit, they may be delivered in stacked
form as blanks which are magazine-fed to a carton
forming and filling unit, or they may be packed in
boxes in nested form to be fed by hand or
automatically to the filling unit. Single-service
containers for quantities of milk from 2 l or more are
used extensively for deliveries to catering
establishments and institutions.
In those cases where the container is made from
plastics or a paperboard/plastics laminate and the
system is of the form-fill type, the risk of
contamination between forming and filling can be
disregarded. When pre-formed blanks or nested
cartons are used, the risk of contamination is low
provided handling is carried out with due attention
to hygiene.
In general, contamination can occur at this stage if
cleaning and disinfection of the filler has not been
carried out efficiently, or if the containers or
container materials are handled or stored in an
unhygienic manner.
Clean and dry, and in some cases controlled
temperature, storage facilities should be provided
for stocks of empty containers or container
materials, and any unused material should be
returned to this store after the days run. Only the
minimum amount of material should be kept
adjacent to the filling area during a run.
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BS 7771:1994
7.1.5 Preparation of containers before filling

The bacteriological condition of the container, and
hence its possible influence on keeping quality, is
dependent on the care which has been exercised in
its preparation.
Single-service containers present little hazard
provided care is always exercised in handling the
empty containers or the materials from which the
containers are formed.
Any re-usable container, i.e. glass bottles and
churns have to be considered contaminated when
returned to the dairy. Inspection and sorting of
containers for re-use is essential. Some will be
unsuitable for re-use and should be discarded;
others will be re-usable but will require hand
treatment before they can be subjected to the usual
conventional treatment; and some may require only
conventional treatment.
The following should be observed in relation to the
preparation of bottles and cans.
a) They should be re-used as soon as possible
after receipt at the dairy. They should be cleaned
and disinfected as described in section 11.
b) Bottle washers and churn washers should be
maintained in a sound and hygienic state.
Detergent solutions should be renewed regularly,
and during and after a run filters should be
cleaned (see section 11).
c) The cleanliness of bottles and churns
(including lids) depends largely on the efficacy of
detergent treatment and subsequent rinsing.
Accordingly, attention should be paid to
temperature and strength of detergent solution.
d) After detergent treatment, bottles and churns
may be expected to be disinfected, and it is
essential that this condition be maintained. The
danger of re-contamination in the hot and warm
rinse sections of bottle washing machines should
be avoided by frequent boiling out of these
sections of the machine with a caustic solution.It
is essential that the rinse tanks are emptied and
disinfected at the end of each days filling
operations.
36
e) The bacteriological quality of the water should

always be satisfactory. If necessary the supply to
the washer should be subjected to a sterilizing
treatment immediately before use.
f) Bottles should be scrutinized as they are
discharged from the washer. Conveyors to the
filler(s) should be as short as possible and hooded
as a precaution against airborne contamination.
Bottle scanning equipment is essential on long
high speed lines.
g) In the case of churns, disinfection is often
achieved by steam jetting followed by hot air
drying. The steam has to be at a sufficiently high
pressure and the air which is used has to be
maintained at a sufficiently high temperature.
In the case of churns, both churn and lid should
be examined after treatment, and the lids
replaced as soon as possible. There should be
only a minimum delay between churn
disinfection and filling.
h) Scale build-up is conducive to contamination.
If the use of sequestering agents in detergents is
inadequate to prevent scaling, water supplies
should be softened or, if available, condensate
used.
7.1.6 Package closure
It is essential that filled bottles or single-service
containers are effectively sealed.
In the case of glass milk bottles the capper action is
vital to proper closure of the bottle and well-trained
operatives will quickly detect unsatisfactory and
loose capping.
In the case of single-service containers the packs
should be sampled at regular intervals,
e.g. start-up, middle of the run, and end of the run,
for the control of leaking containers. In most cases
the leaks occur at the seals.
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BS 7771:1994
7.2 Storage and handling of milk after

packaging
When pasteurized milk has been packaged and the
container has been effectively sealed there is no
chance of further contamination, and any
subsequent deterioration in quality can only be due
to the growth of the micro-organisms present at that
stage. If, however, sealing is imperfect, e.g. a
loose-fitting aluminium cap on a glass bottle,
contamination will take place.
The essential practices in storage and handling of
pasteurized milk after filling are as follows.
a) Keep the milk as cold as possible in order to
restrict the growth of micro-organisms to a
minimum.
b) Take all possible steps to see that the milk is in
the consumers possession as soon as possible.
c) Avoid exposure of the milk to light, particularly
direct sunlight, to avoid off-flavour development.
The following aspects should be noted.
1) The temperature of the milk in the container
after filling should be as low as possible. Without
delay the filled containers should be put into the
cold store at the farm or processing dairy, the
temperature of which should be between 3 C
and 5 C. In the hotter periods of the year it may
be difficult to maintain such low temperature
conditions of storage without full precautions,
e.g. minimizing the opening of doors and
providing suitable cold air curtain arrangements
at entrances and exits.
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2) Packaged milk should be transported under

refrigeration to distribution depots or direct to
retail outlets.
Packaged milk should be protected from adverse
weather conditions, i.e. direct exposure to heat,
light and rain.
3) Cold storage facilities should be provided at
distribution depots. Low temperatures of 3 C
to 5 C should be maintained.
4) From the pasteurizing premises or distribution
depot to the shop or household, pasteurized milk
is rarely kept under refrigerated conditions in the
United Kingdom. Any means of protecting the
low temperature of the milk as it leaves the
pasteurizing or distribution premises and before
delivery is helpful in maintaining quality. At the
shop or supermarket, milk is usually kept in a
refrigerated cabinet, which affords temperature
protection until it is sold.
37
BS 7771:1994
Section 8. Hygiene management

NOTE High standards of hygiene management are imperative
in the dairy industry to prevent food poisoning, food spoilage, loss
of productivity, pest infestation or infringement of statutory
requirements. In addition to well designed and managed
premises the processes and practices having an influence on
hygienic quality need to be understood and properly managed.
8.1 Hazard Analysis and Critical

Control Point system (HACCP)
8.1.1 General
Managers of milk processing establishments are
recommended to adopt the principles of the HACCP
system2) as part of their hygiene and quality
management policy.
The HACCP system identifies specific hazards and
preventative measures for their control to ensure
the safety of food. The main focus of HACCP is to
identify and control the microbiological, physical
and chemical hazards affecting food safety.
However, the scope of a HACCP system can be
widened and applied to other criteria such as
microbiological quality, so as to minimize product
spoilage.
8.1.2 Application
The practical application of HACCP has to be
specific to each site and process. The following
principles should be used:
a) analysing the potential food hazards in the
dairy business operation;
b) identifying the points in those operations
where food hazards may occur;
c) deciding which of the points identified are
critical to food safety the critical points;
d) identifying and implementing effective control
and monitoring procedures at those critical
points;
e) reviewing the analysis of food hazards, the
critical control points and the control and
monitoring procedures periodically and whenever
the dairy business operations change.
8.1.3 Hygiene practices (personnel)
8.1.3.1 Personal hygiene is of utmost importance in
the dairy industry. The following are subject to
statutory requirements.
a) All operatives have to wear clean, washable
overalls and footwear, and headgear which
completely encloses the hair.
b) If operatives are engaged on several duties,

then separate protective clothing has to be
provided for use in the dairy.
c) Adequate hand washing facilities,
i.e. non-hand operable taps (e.g. foot or knee
operated), fitted with a constant supply of hot and
cold water and suitable hand drying facilities
have to be provided within the dairy for the use of
operatives. The waste should discharge over an
external trapped gully where practicable.
d) Soap, towel and nailbrush have to be provided
adjacent to the hand basin.
e) No person suspected of being infected with any
notifiable disease is allowed to work in the dairy.
f) Any person suffering from bowel or stomach
disorders has to notify his employer prior to
commencing work and check with his/her doctor.
g) Any cuts or abrasions have to be covered with
waterproof plasters (not flesh coloured).
h) A first aid kit has to be provided.
i) Spitting and the use of tobacco or snuff is
prohibited.
8.1.3.2 All staff should be made aware of the
dangers of infection of pasteurized milk after the
heat treatment process and of the need to ensure
that no worker with any condition likely to cause
infection is engaged in duties in milk processing or
packaging or other dairy duties.
8.1.3.3 All staff have to be trained in hygiene
matters as required under the Food Safety Act 1990
for England, Wales and Scotland and the Food
Safety (NI) Order 1991 for Northern Ireland.
8.2 Cleaning and disinfection of dairy

equipment
8.2.1 Milk is a highly perishable product subject to
microbiological spoilage before and after
pasteurization. All milk contact surfaces are a
potential source of contamination demanding high
standards of hygiene in the dairy and effective
methods for cleaning and disinfecting all equipment
used. Managers and supervisory staff of the
processing dairy should be thoroughly trained in the
fundamentals of cleaning and disinfecting processes
and the hazards associated with the use of related
chemicals. Good knowledge of dairy hygiene is
essential, including potential sources of problems.
2) WHO Codex Alimentarius Commission (1991). Report of the twenty-fifth session of the Codex Committee on Food Hygiene,
Washington DC. 28 October 1 November 1991 Alinorm 93/13 Appendix VI. p. 75-80.
WHO Codex Alimentarius Commission (1993). Report of the twenty-sixth session of the Codex Committee on Food Hygiene,
Washington DC. 3-5 March 1993 Alinorm 93/13A. Guidelines for the application of the Hazard Analysis Critical Control Point
(HACCP) System. Alinorm 93/13.
38
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BS 7771:1994
Dairy operatives should be given instruction

relating to the following.
a) The objectives of cleaning and disinfecting
dairy plant and equipment.
b) The importance to human health and product
quality of their actions.
c) Responsibilities relating to plant operation and
maintenance, cleaning schedules and quality
control.
d) The safe use and storage of chemicals as
interpreted in the Control of Substances
Hazardous to Health Regulations 1988 (see 2.9)
8.2.2 BS 5305:1984 describes procedures for
cleaning and disinfecting (sometimes jointly
referred to as cleansing) of plant and equipment
used in the dairying industry and should be
consulted. It covers the use of detergents,
disinfectants and combined detergents and
disinfectants.
It provides the basis for cleaning and disinfection to
which recommendations from commercial suppliers
of chemicals may be added.
8.3 Fundamentals of the cleaning

process
8.3.1 Basic steps in cleaning, and components
of detergents
In all cleaning processes in the dairying industry
every endeavour should be made to carry out each of
the following steps. They are normally all necessary
for successful cleaning and any subsequent or
combined disinfecting process:
a) a preliminary rinse with water immediately
after processing has ceased to remove gross soil,
which is defined as milk residue, scale or other
deposits that have to be removed from plant and
containers during the cleaning process;
b) a cleaning treatment with detergent solution
so that the soiled surface is freed from soil;
c) one or more rinses of the cleaned surfaces with
clean water so that they are freed from released
contamination and detergent solution.
During cleaning treatment with the detergent
solution several processes occur:
1) wetting of the soiled surface;
2) removal of the soil from the surface by solution,
emulsification, chemical action and/or
mechanical action;
3) dispersion and suspension of the undissolved
soil within the bulk of the solution.
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During the subsequent rinsing process it is essential

that the detergent has good rinsability properties,
that is that the detergent solution should be capable
of holding the soil in suspension whilst the solution
is being diluted during the rinsing operation, so that
there is no redeposition. This also means that the
detergent solution should leave no residual
detergent film on the rinsed surface.
Detergent products are formulated from a wide
range of materials each of which contributes a
desired property to the final product. Components of
detergents fall into several categories.
i) Inorganic alkalis, including sodium hydroxide
(caustic soda), phosphates, silicates and
carbonates which contribute the desired
alkalinity, buffering and rinsing power. They are
effective in removing soil from equipment
surfaces.
ii) Inorganic and organic acids which are used in
formulations intended for the removal of
tenacious soil, such as milkstone.
iii) Sequestering agents, including sodium
polyphosphate and ethylenediaminetetra-acetic
acid (EDTA) and its salts, which are included in
detergents to prevent hard water scales or to
prevent or remove milkstone. The rinsing
properties of a detergent solution may be
improved by their inclusion.
iv) Surface active agents, which give wetting,
emulsifying or dispersing properties to the
detergent.
v) Suspending agents, which keep undissolved
soil in suspension.
vi) Inhibitors, which minimize the corrosive
attack of acids and alkalis on metals.
vii) Anti-foaming agents, which may be used for
special applications.
viii) Chemical disinfecting agents, which may be
incorporated with detergents to provide products
which both clean and disinfect.
Only disinfectants and chemical agents approved
by the authorities concerned, in accordance with
the appropriate dairy legislation, are permitted
as alternatives to steam or hot water for the
disinfection of milk equipment.
8.3.2 Proprietary detergent products
Most milk processors in the scale of pasteurization
covered in this code of practice will purchase
detergent materials and disinfecting agents as
ready-to-use products rather than for compounding
or mixing in the dairy.
39
BS 7771:1994
When considering the purchase of a proprietary

brand of detergent, the user should inform the
supplier of the exact purpose for which the product
is to be used and supply any other relevant
information which is required, e.g. the hardness of
the water, the make, size and normal operating
conditions of the equipment in use.
Suppliers of proprietary dairy detergents will
normally provide the milk processor with the
following.
a) A clear statement indicating the cleaning
operations for which the products are intended.
b) Full and easily understood instructions on
their use, the means of testing solution
concentrations and any special handling
instructions.
c) A general guide to the nature of the product
and, in the case of simple detergents, an
approximate analysis.
d) Advice on storage of the product.
e) Information required by the Health and Safety
at Work etc. Act 1974 and related legislation on
safe storage and usage of the products.
f) Technical service.
The appropriate section of BS 5305 should be
consulted for further information on detergency.
Milk processors are strongly recommended to
consult their detergent supplier on any point on
which there is doubt.
8.3.3 Descaling or removing milkstone
Periodic treatment by circulating an acid descaling
solution may be necessary. Use, preferably, a
solution of a proprietary milkstone remover as
recommended by the manufacturer or alternatively
phosphoric acid of BP quality (300 ml in 50 l of water
at 45 C to 50 C). Rinse with cold clean water,
followed by recirculation of hot
detergent/disinfectant solution and a final rinse
with cold clean water.
8.4 Fundamentals of the disinfecting

process
8.4.1 General
In the context of the dairy industry, disinfection is
defined as a process that reduces the number of
bacteria and other micro-organisms in dairy plant
and utensils to a level consistent with acceptable
quality control and hygienic standards.
Effective cleaning of the surfaces of dairy equipment
is essential for effective disinfection.
40
If inadequately cleaned equipment is subjected to a

disinfection process one or more of the following
may happen.
a) Micro-organisms present in soil residues will
be protected from contact with chemical
disinfectants and, to some extent, from the effects
of heat.
b) The strength of any chemical disinfecting
solution and hence its effectiveness may be
reduced by excessive quantities of soil.
c) Heat disinfection will render the residual soil
more resistant to subsequent cleaning processes.
d) Micro-organisms surviving either heat or
chemicals may multiply in moist soil residues
and, if sufficient time elapses before use, the
equipment may become seriously contaminated.
8.4.2 Types of disinfecting processes
8.4.2.1 General
Disinfecting processes may be divided into those
which are dependent on heat and those which are
dependent on chemical agents.
8.4.2.2 Heat disinfection
In the case of heat disinfection of dairy plant and
equipment the efficiency of the process depends on
the temperature reached, the time the temperature
is maintained, and the humidity. The required
degree of microbial destruction will be achieved
provided the method of application and the design of
the equipment permit adequate penetration of heat
to all parts of the plant or equipment. Temperatures
should be measured by means of thermometers of
known accuracy.
Steam at atmospheric pressure has several
applications in the disinfection of dairy equipment.
While it will not destroy all bacterial spores it is
effective against vegetative bacteria found as
contaminants in equipment used in milk
pasteurization.
Hot or boiling water has application in similar
circumstances for disinfection. Circulation of water
at a temperature of 80 C or higher, for 20 min is
considered an effective treatment to destroy
vegetative bacterial cells.
8.4.2.3 Chemical agents
Chemical disinfecting agents and combinations of
detergents and disinfecting agents used in the
United Kingdom for the disinfecting of dairy plant
and equipment on farms and in most dairy
applications including pasteurizing plant are
approved for the purpose. The approval for use in
England and Wales is given by the Minister of
Agriculture, Fisheries and Food, the Secretary of
State for Social Services and the Secretary of State
for Wales.
BSI 06-1999
BS 7771:1994
Chemical disinfecting agents approved for use in

England and Wales may also be used in Northern
Ireland.
In Scotland the Secretary of State approves
chemicals for use as bactericidal agents in dairy
applications. Information on products approved for
use in Scotland is available from the Scottish Office
Agriculture and Fisheries Department.
The efficacy of all approved disinfecting agents is
influenced by concentration, contact time,
temperature, organic matter (soil), pH, water
hardness, combination with detergents and types of
micro-organisms present on the equipment.
All chemical disinfecting agents lack penetrative
power, and micro-organisms in milkstone and in
crevices may survive treatment. Air-dried milk
residues may hinder immediate contact between the
chemical and the micro-organism.
Where chemical disinfecting agents are applied
after the cleaning process it is essential that the
equipment is first rinsed free of detergent residues
and suspended soil.
Combination of a chemical disinfecting agent with
compatible detergents which bring about soil
removal enables cleaning and disinfection to be
effected in one operation.
As normally used, chemical disinfecting agents are
not effective against bacterial spores.
The main chemicals used as disinfecting agents in
the dairy industry include the following.
a) Chlorine. Sodium hypochlorite solutions and
brands of chlorinated trisodium phosphate may
be used as disinfecting agents alone. Sodium
hypochlorite may be added to solutions of suitable
detergents to provide dual-purpose (cleaning and
disinfecting) solutions.
Organic chemicals which release chlorine may be
formulated with detergents and marketed in
powder form.
An approved hypochlorite solution as available
from the supplier and within its recommended
shelf life should contain not less than 8 % (m/m)
and not more than 12 % (m/m) of available
chlorine.
For practical purposes the available chlorine
content may be taken as 10 % (m/m) so that the
dilution of one part of an approved commercial
hypochlorite in 1 000 parts of water gives a
solution containing approximately 100 mg/l of
available chlorine.
BSI 06-1999
Except with products specially recommended for

repeat use, only freshly prepared solutions
should be used.
Chlorine-releasing chemicals are corrosive to
most metals including stainless steel. At low
concentration in alkaline conditions, at low
temperature and with short contact time, these
corrosion hazards are minimized and the
disinfecting action remains effective.
Hypochlorite solutions may be used safely and
effectively on product contact surfaces provided
such precautions are taken.
If previously cleaned equipment is to be
disinfected with hypochlorite solutions, the
following precautions are necessary.
1) The equipment should be rinsed free of
detergent residues.
2) If acid has been circulated to remove
milkstone, all traces of acid should be removed,
and for this purpose circulation of an alkaline
solution is advisable.
3) It is preferable to disinfect the equipment
just prior to use to avoid the risk of corrosion
resulting from traces of hypochlorite
remaining for some hours in the equipment.
Disinfecting solutions containing chlorine
should not be left in contact with metal
equipment overnight.
4) Because of their construction, stainless steel
plate-type heat exchangers are particularly
prone to corrosion by chlorine-releasing
chemicals and the precautions listed in
items 1), 2) and 3) are essential to prevent
damage to such equipment.
5) It is unnecessary and may be harmful to the
equipment to use solutions containing more
than 200 mg/l of available chlorine at a
temperature greater than 40 C for a period of
longer than 10 min. For most purposes
disinfection using cold solutions
containing 100 mg/l of available chlorine for a
period of 15 min is adequate.
6) Where possible, the available chlorine
content of disinfecting solutions should be
checked at the time of use.
All chlorine-based disinfecting agents should
be used in accordance with the manufacturers
instructions.
41
BS 7771:1994
b) Quaternary ammonium compounds (QACs).

A number of QACs are approved as disinfecting
agents in the dairy industry in England and
Wales and Northern Ireland. They are not
recognized as approved bactericidal agents for
disinfection of dairy plant and equipment in
Scotland. QAC disinfecting agents should not be
added by the user to detergent solutions for
combined cleaning and disinfection because the
QAC may be seriously inactivated by certain
detergent ingredients.
Approved combinations of detergents and
quaternary ammonium compounds are available.
The more important properties of QACs which
influence their performance as disinfecting
agents and their use in the dairy industry are as
follows.
1) In concentrated form they are highly stable
and have a long shelf life.
2) Compared with undiluted hypochlorite they
are much safer to handle although they may
cause skin irritation.
3) Their high surface activity and consequent
foaming properties makes them unsuitable for
circulation or other mechanical application in
most pipeline systems where foam production
may hinder effective circulation and make
rinsing difficult.
4) Normal use concentrations are 150 mg/l
to 250 mg/l of QAC at temperatures greater
than 40 C and with a contact time of not less
than 2 min.
Low concentration of QAC (e.g. less
than 50 mg/l) and low application
temperature (e.g. less than 10 C) are
conditions which cause these disinfectants to
be selective in their bactericidal activity.
Under these conditions they are less effective
against gram-negative bacteria such as
coliforms and psychrotrophs than they are
against streptococci and other gram-positive
bacteria.
Combinations of adverse conditions may
encourage the development of a QAC-resistant
flora on imperfectly cleaned equipment
treated with QAC solutions.
5) The bactericidal effectiveness of QACs will
be impaired by the presence of organic matter
such as milk.
All QACs should be used in accordance with
the manufacturers instructions.
42
c) Other chemical disinfecting agents. Other

chemical agents which may have application in
the milk processing farm or dairy for disinfecting
purposes include complexes of iodine with
non-ionic surface active agents (known as
iodophors), amphoteric (ampholytic) surface
active agents, acidic disinfecting agents,
peracetic acid, biguanides and sodium hydroxide
(caustic soda).
The suitability of methods and materials for
disinfecting plant and equipment used on the
dairy farm and in the milk processing operations
are summarized in Table 4 of BS 5305:1984.
Chemicals should be used only in accordance
with the manufacturers instructions.
8.5 Inspection and sampling

procedures for determining the
hygienic condition of dairy plant
8.5.1 General
The main reason for determining dairy plant
hygiene is to ensure that the equipment will not
contaminate the product with micro-organisms
which might lead either to product spoilage or to
food poisoning.
If contamination of the equipment has taken place,
the use of systematic inspection, sampling and test
procedures will allow the dairy staff to identify
where in the pasteurization process bacteriological
infection or chemical contamination has occurred
and corrective measures can be more easily made.
Hygiene checks also provide information to the milk
processor on effectiveness of the practices which are
in use for the cleaning and disinfection of the
pasteurization installation.
8.5.2 General instructions
The demands for efficiency in cleaning operations
vary from dairy to dairy depending on supervision,
the scale of production and on quality requirements.
Systematic visual inspections, chemical and
physical analysis and interpretation of laboratory
and production records are important in ensuring
consideration of factors such as visible soil residues,
malfunction of equipment, residues from cleaning
materials and corrosion of equipment surfaces.
Bacteriological tests provide additional information
but are not alternatives to visual checks.
Sampling for microbiological examination should be
carried out only by persons who have been trained
in sampling for this purpose.
The frequency of sampling depends on several
factors including the duration of pasteurizing and
packaging operations, the availability of laboratory
resources and on costs of plant checks.
BSI 06-1999
BS 7771:1994
Tests made for quality control purposes on the

pasteurized milk provide an indirect check on the
efficiency of cleaning and disinfecting of the dairy
equipment.
8.5.3 Inspection and sampling procedures
8.5.3.1 Visual inspection
Visual inspection is the most rapid, cheapest and
easiest method of examination. The most important
parts should be carried out daily. It is one of the
most important methods available to the
producer-processor or small dairyman for ensuring
the quality of pasteurized milk.
An immediate and valuable indication of the
cleanliness of the pasteurization installation and
ancillary equipment can be obtained by systematic
inspection of the accessible parts of the equipment.
The inspection should include the outer surfaces of
all items of equipment. These should be clean and
attractive and should indicate that the operatives
are taking care of the appliances under their
control.
Visual inspection should include all storage tanks,
balance tanks, agitators, pumps, pipe fittings with
their washers and gaskets, filling machine bowls,
crates, conveyors and bottles and packaging
materials.
Visual inspection should be made using a bright
torch or by ultraviolet light. No sign of fluorescence
should be detectable when the surface is carefully
inspected with long wavelength (340 nm to 380 nm)
ultraviolet light.
A sterile swab, clean disposable muslin or strong
tissue paper may be used to wipe the plant surface
to check for evidence of a film or soil residue on
improperly cleaned equipment.
Greasy residues or thin hard films on plant surfaces
indicate inadequate or unsuitable detergents and/or
too low temperatures for manual cleaning
operations or inadequate time/temperature
combinations for the circulation of cleaning
solutions. Inadequate final rinsing may be a
contributory factor in the formation of surface films.
BSI 06-1999
More extensive residues of milk indicate poor

training or cleaning practices of the staff. Attention
should be given to ensuring complete drainage of all
parts of the installation since bacteria develop more
rapidly in moist conditions.
Milk pumps and valves should be examined at
regular intervals as advised by the manufacturer,
and seals, rubbers and gaskets should be inspected.
Spray balls of cleaning systems should be inspected
to ensure that no holes are blocked.
After examination, plant items that have been
inspected should be disinfected following
re-assembly and before use.
If visible residues are found in the equipment, the
production and laboratory staff should trace the
cause of the problem and take suitable measures to
remedy the fault. There is no value in making a
bacteriological check on visually dirty equipment.
8.5.3.2 Sampling procedures
Because many surfaces are inaccessible and because
sampling and subsequent laboratory examinations
are expensive, a careful selection of sampling points
should be made.
Particular attention should be given to parts which
are difficult to clean and disinfect, e.g. recesses,
pipeline elbows, valves, agitator shafts and paddles,
gauges, thermometer probe points.
The appropriate time to sample the equipment is
after the normal cleaning and disinfecting
operations and, if necessary, before re-use of the
equipment.
Swab tests and rinse techniques are used to assess
the hygiene condition of plant surfaces coming into
contact with milk before, during and after the
pasteurization process.
Sample by techniques detailed in BS 4285-1.1:1991.
8.5.3.3 Microbiological examinations
Test by swab and rinse techniques as detailed in
BS 4285-4:1991.
43
BS 7771:1994
Section 9. Quality
9.1 Statutory tests applied to
pasteurized milk
9.1.1 General
The laboratory facilities available to the producer
processor and small pasteurizing dairy are likely to
be limited and may not meet those required to carry
out the range of legally prescribed tests or chemical
and microbiological examinations which are
considered to be essential to safe and efficient
working practices.
In cases where laboratory facilities are very limited
or non-existent, it is recommended that the milk
processor enter into a contract with a laboratory
organization proficient in milk testing and
preferably with expertise in milk processing
operations so that the results of tests can be
properly interpreted.
The outline proposals for testing frequency
(see Table 4) are considered the minimum
requirements by which the milk processor can judge
the performance of his operations.
9.1.2 Phosphatase test
9.1.2.1 General
Historically, tuberculosis organisms were the most
significant pathogenic bacteria in milk. The enzyme
phosphatase, which is always present in raw milk,
has a thermal destruction temperature slightly
higher than that at which tuberculosis organisms
are destroyed.
The prescribed time/temperature combinations for
the pasteurization of milk as specified in UK dairy
legislation ensure the destruction of phosphatase
and thus provide a simple method of determining
whether a milk has been adequately heat treated to
destroy pathogenic bacteria.
The test is very sensitive. It is based on the ability
of phosphatase to release quantitatively the
yellow-coloured p-nitrophenol from disodium
p-nitrophenol phosphate when this compound is
incubated with milk at 37.5 C 0.5 C for 2 h. The
test procedure has to be used as prescribed by
legislation.
Another sensitive procedure involves the
fluorimetric measurement of alkaline phosphatase
(ALP) activity using the Fluorophos Test System
now adopted as an IDF provisional standard
(IDF 155:1992).
The required time/temperature conditions of
pasteurization have been achieved when milk gives
a negative phosphatase test, i.e. a reading of 10 4g
or less of p-nitrophenol per millilitre of milk. The
target standard should be 0 4g per millilitre of milk.
44
9.1.2.2 Possible cause(s) of test failure

If a sample of heat-treated milk fails the
phosphatase test it indicates that the
time/temperature conditions for pasteurization
have not been achieved.
Only slight deviation from the prescribed minimum
time/temperature conditions for pasteurization
results in a positive phosphatase test.
If raw milk gains access to pasteurized milk, a
phosphatase test on the resultant mixed milk is
likely to give a positive phosphatase test. The test
will detect the presence of as little as 0.2 % (m/m) of
raw milk admixed with pasteurized milk.
Laboratory staff should be skilled in carrying out
the test which is sensitive to impurities in reagents
and/or contamination of glassware which may result
in false positive results.
Where systematic checks fail to establish the cause
of intermittent or spasmodic phosphatase test
failures, the cause may be the presence of
extraneous materials in the milk sample. These
have been shown to include phenolic substances
from environmental pollution such as road works
using tar, smoke from incinerators, laying of floors,
tiling, etc. involving use of materials containing
phenols. A test failure may result where phenolic
substances in a returned bottle have not been
completely removed by normal bottle washing
procedures or where phenolic compounds are
derived from the farm environment.
Failure due to deficiencies in processing methods
may be distinguished from those due to the presence
of extraneous materials by arranging for additional
testing of the suspect sample.
The suspect sample is split into two parts. The first
part is tested in the normal way. The second part is
laboratory pasteurized in accordance with
BS 4285-3.2:1991 and then tested. If the first
subsample gives a positive result and the second
subsample a negative result, a processing deficiency
is indicated.
If both subsamples give positive results it may be
assumed that the failure is due to an extraneous
cause or false positive.
Instances have been noted of reactivation of the
phosphatase enzyme during storage of pasteurized
milk which gave a negative result immediately after
processing.
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BS 7771:1994
Table 4 Summary of laboratory tests concerned with pasteurized milk:

causes of failure: remedial action
1
Specified test
2
3
Frequency of testing
a) Small
b) Small
Possible cause(s) of failure
dairy
dairy with
to meet satisfactory
using
fully
standard
service of equipped
outside laboratory
laboratory
Phosphatase test Weekly

Target level:
0 4g
p-nitrophenol/ml
milk. Reading
of 10 4g or less of
p-nitrophenol/ml of
milk is a statutory
requirement.
Plate count
at 21 C after
incubation at 6 C
for 5 days.
Target level:
k 50 000/ml.
Coliform count
Target level:
absent.
Peroxidase test
Target level:
positive reaction
NOTE Pasteurized
milk which shows a
negative reaction is
authorized providing
that the milk is labelled
as high temperature
pasteurized.
BSI 06-1999
Investigate and remedy as appropriate
Check the holding temperature and

milk flow rate. Ensure that the flow
divert is set to activate at 71.7 C or
above and is operating correctly.
Check gaskets and heat exchange
plates in the regeneration section and
flow diversion valve for leaks. Avoid
contamination of laboratory
glassware and reagents used for the
test, especially by phenols, to avoid
false positive results.
Test failures indicate post
Weekly Daily
Post pasteurization
pasteurization contamination and
contamination from
pipelines, storage tanks unhygienic practices. Intensify
hygiene practices especially for
or milk filling
equipment involved after heat
equipment. Water
treatment. Ensure that returnable
supplies may be
containers are thoroughly cleansed.
contaminated with
Chlorinate final rinse water in bottle
cold-tolerant bacteria.
washers. Check water quality.
Weekly Daily
As above
As above.
Routine testing for coliforms provides
a reliable indication of the extent of
post pasteurization contamination.
Monthly Monthly The enzyme peroxidase Check the holding temperature and
is destroyed at 78 C
milk flow rate.
in 15 s thus indicating
Check all thermometers controlling
excessive temperatures the temperatures applied in the
during the HTST process heating and holding sections. Check
and/or repeat
the functioning of the hot water set.
pasteurization.
Plate count
Weekly
at 30 C.
Target level:
< 30 000 ml
(advisory test, not a
statutory
requirement)
Pathogenic
micro-organisms
Target level:
absent in 25 g
Daily
Daily
Failure to use the correct

time/temperature
conditions to inactivate
phosphatase enzyme
present in raw milk.
Otherwise the failure
may be due to
contamination with raw
milk.
Excessively high
numbers of
heat-resistant bacteria in
the raw milk. Unhygienic
conditions during storage
of raw milk. Unhygienic
conditions in pipelines
storage tanks and
packaging equipment,
i.e. post pasteurization
contamination.
When indicated by As advised under plate
the results of other count and coliform test.
preliminary tests
Check the quality of raw milk

supplies; time and temperature of
milk storage; hygienic condition of all
equipment in use.
As advised under plate count and

coliform test.
Exclude milk from human
consumption.
Notify enforcement authority.
45
BS 7771:1994
9.1.2.3 Investigation and remedial action
9.1.3 Plate count

a) Make certain that no modifications have been
made to the plant since the last holding time test
was made.
b) Check that rubber gaskets on plate heat
exchangers vent to atmosphere in case of
abnormal pressure-build up. Leakage grooves
should not be blocked. Gaskets should not have
been flattened to the point where they are
ineffective.
c) Check the temperature of pasteurization with
an accurate reference thermometer of known
accuracy; check that the recorder corresponds
with this setting.
d) Undertake tests with water under exactly the
same conditions as apply to milk to ensure that
flow diversion takes places at the correct
temperature, i.e. 71.7 C. Check that the speed of
response of the controlling instrument is good.
e) Check heat exchanger plates by visual
inspection and with a dye penetrant method for
holes or cracks which could permit raw milk
gaining access to the pasteurized milk during
regeneration cooling.
9.1.3.1 General
NOTE An X-ray examination service is available from some

manufacturers of heat exchange plates.
f) Check that the flow controller is in position and

is controlling the flow rate to the designed plant
capacity.
g) Before starting up the plant make sure that the
clean/run switch is set to run.
h) Check the hot milk temperature recorder
against a calibrated thermometer for accuracy of
hot milk temperature. Maintain a constant watch
that the temperature controller is working
correctly throughout the run.
i) Check if the flow diversion valve leaks under
pressure.
j) Check that the flow diversion point controller is
set to not less than 71.7 C.
k) Check whether any blank ends are not purged
of raw milk.
l) Check for the presence of scale.
m) Check that there is no leakage of raw and
pasteurized milk at the valves.
46
The number of bacteria present in pasteurized milk

as determined by the plate count test is a measure
of how many bacteria have survived the heat
treatment plus additional bacteria which have
entered the milk after heat treatment from plant
and container surfaces and, to a lesser extent, from
the environment of the milk processing and
packaging operations.
The number of bacteria in pasteurized milk is also
influenced by the temperature and time for which
the milk has been held before testing.
Individual milk supplies vary in the proportion of
the bacteria present which are not destroyed by
pasteurization.
Heat resistant (thermoduric) bacteria may increase
in numbers and be protected by surface scale in
milking machine installations or in raw milk
pipelines or storage tanks in the pasteurizing
premises.
The plate count of raw milk is a measure of the
bacteriological quality of raw milk as influenced by
the production conditions on the farm and the
results of these tests is used as a means of
determining the suitability of milk supplies for
pasteurization.
If heat treatment has not been carried out at the
correct time/temperature combination, bacterial
numbers will be higher than expected.
If the phosphatase test is satisfactory then test
failures may be due to excessively high numbers of
heat-resistant bacteria in the raw milk resulting
from abnormal numbers of thermoduric bacteria in
one or more farm supplies or from contamination of
the farm supplies in badly disinfected tankers, raw
milk storage tanks and pipelines.
Unsatisfactory cleaning and disinfection of the heat
exchanger and the pipelines, pasteurized milk tank
and packaging equipment is a likely cause of test
failure.
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BS 7771:1994

a) Check on the time and temperature of heat
treatment and the operation of the pasteurizing
plant as shown by the heat treatment record
charts.
b) Inspect all plant items to assess effectiveness
of cleaning and disinfecting routines.
c) Check on the time and temperature of storage
conditions for raw and pasteurized bulk and
packaged milks.
d) Undertake swab and/or rinse tests as part of a
hygiene inspection provided the plant appears to
be in a thoroughly cleansed state.
9.1.4 Plate count on samples of pasteurized
milk incubated at 6 C for 5 days
9.1.4.1 General
This test is a measure of the bacteria which can
grow at refrigerator temperature such as would be
encountered in retail sales through shops,
supermarkets, etc.
Psychrotrophic bacteria grow in pasteurized milk
under refrigeration and result in spoilage including
rancid and bitter flavours.
Failure to meet the test standard is due to
post-pasteurization infection from pipelines, storage
tanks, packaging machines and milk bottles.
A major source of contamination with
psychrotrophic bacteria is the finished (pasteurized)
milk tank.
Final rinse water used after plant cleaning and
disinfection may be an important source of
psychrotrophic contaminants which will lead to
infection of several plant items if the water is not
disinfected before use.
a) Carry out hygiene inspection of the items of
plant.
b) Use laboratory tests to check for point(s) after
pasteurization where contamination is taking
place.
c) Intensify hygiene practices especially for
equipment involved after heat treatment.
d) Monitor cleaning and disinfection of the
finished milk tank and any cleaning-in-place
procedures.
BSI 06-1999
e) Chlorinate the final rinse water if the quality

of the water supply is suspected. Automatic
chlorine dosing equipment should be used to give
consistent and accurate dosing to the required
concentration.
f) If laboratory tests indicate psychrotrophs
present in the milk at the outlet of the
pasteurizer, check for plant sterility and also for
pinholes in the regeneration and cooling sections
of the heat exchanger.
9.1.5 Coliform count test
9.1.5.1 General
Pasteurized milk should be free from coliform
bacteria because they do not survive the
time/temperature conditions of heat treatment.
The presence of coliform bacteria indicates
post-pasteurization contamination or infection of
the properly pasteurized milk by leakage of raw
milk or water in the regeneration or cooling sections
of the heat exchanger by way of perforations in the
heat exchanger plates.
In laboratory control the coliform test should be
made on all first-milk-through samples of
pasteurized milk taken during hygiene checks.
Complete absence of coliform bacteria in a 1 ml
inoculum should be set as the required standard of
plant hygiene.
These include the following.
a) Unsatisfactory cleaning and disinfection of the
heat exchanger and any or all of the
post-heat-treatment items of equipment.
b) Badly cleaned and disinfected returnable
containers.
c) Water supplies contaminated with coliform
bacteria being used for rinsing of equipment.
d) Perforations in heat exchanger plates in
regeneration and cooling sections of the plate
pack where coliforms may be present in the raw
milk and cooling water.
a) Check the cleaning and disinfection procedures
applied to all items of plant. Particular emphasis
should be given to equipment items coming into
contact with the pasteurized milk.
b) Check the sterility of returnable containers
such as glass bottles and milk cans.
c) Test the bacteriological quality of water
supplies used for rinse purposes and, if
necessary, chlorinate.
47
BS 7771:1994
d) Use visual inspection and a dye penetrant test

to check for perforations in plate heat exchanger
plates.
e) Check that the plant is being used as specified
by the manufacturers to ensure that no source of
infection on the raw milk side of the plant is open
to the flow of pasteurized milk.
9.1.6 Peroxidase test
9.1.6.1 General
This test is applied to detect pasteurized milk which
has been heated above the maximum temperature
of 78 C for 15 s.
These include the following.
a) Defects in plant control or thermometers
leading to excessively high temperatures in the
heating medium.
b) Defects in the hot water set which result in
lack of control of the temperature of the hot water
circulated through the heating section of the
plate heat exchanger.
c) Any restriction which may impair the flow rate
of milk.
a) Inspect the hot water set for defects.
b) Check the thermometers used in indicating
and control positions.
c) Check for impediments to the milk flow rate.
9.1.7 Sampling guidelines
The following action is recommended in respect of
sampling by enforcement authorities and the dairy
industry for microbiological testing:
a) samples should be taken only from the
production line;
b) samples should represent normal running
conditions;
c) samples should be whole, i.e. a complete
bottle or single-service container;
d) if pre-incubated tests are to be undertaken,
separate, unopened containers are essential;
e) additional samples are required for
temperature monitoring;
48
f) processors are recommended to take parallel

samples for their own use;
g) processors should be advised by the
enforcement authorities of all results.
Guidelines for the sampling and testing of
pasteurized milks for enforcement purposes
(February, 1989) were agreed by the following
organizations:
Association of Public Analysts
Dairy Trade Federation
Institution of Environmental Health Officers
National Farmers Union
Public Health Laboratory Service.
9.2 Tests undertaken to fulfil other

statutory requirements
Attention is drawn to the need to fulfil statutory
requirements concerning the nature, substance and
quality of foods, adulteration of milk and
composition of drinking milks. The owners of dairy
establishments should undertake periodic checks as
follows.
a) Fat content of whole milk (unstandardized)
with a minimum of 3.5 % milk fat by mass (m/m).
b) Fat content of semi-skimmed milk to be not
less than 1.50 % and not more than 1.80 % by
mass (m/m).
c) Fat content of skimmed milk to be not more
than 0.30 % by mass (m/m).
d) The whole milk, semi-skimmed milk and
skimmed milk to be free from added water.
e) Antibiotic residues are not to be detectable.
9.3 Frequency of sampling

Sampling programmes should be designed in
accordance with HACCP principles, supported by
advice from the enforcement authority.
9.4 Quality defects in pasteurized milk

A number of quality defects are liable to occur in
pasteurized milk and affect its shelf life and general
acceptability. These are summarized in Table 5.
BSI 06-1999
Common name
of defect
Effect on milk quality as perceived

by the consumer
Cause
Associated or contributory
conditions
Investigation and/or remedy
Bitty cream
When pasteurized milk is added to tea

and hot beverages small white particles
appear and float on the surface along
with droplets of free fat.
Germination and growth of spores of

Bacillus cereus which are not
affected by pasteurization
temperature. Enzyme produced by
B. cereus destroys the fat globule
membrane producing the small
white particles and free fat.
Dusty weather results in conditions

leading to contamination of raw milk
supplies with spore-forming
bacteria. Warm weather results in
ideal conditions for germination and
growth of the spores of B. cereus in
empty milk bottles and in
pasteurized milk before delivery.
Practise strict hygiene in the dairy

especially the equipment after the
pasteurizer, and returnable containers.
Package the milk at as low temperature
as possible e.g. below 5 C. Cold store the
packed milk at 4 C to 5 C. Reduce as far
as possible exposure of packaged milk to
warm conditions e.g. above 10 C.
Poor keeping
quality
The milk develops off-flavours,

unpleasant odours or altered
appearance within the normal keeping
quality of the pasteurized milk, which
when held under efficient refrigerated
storage conditions of 5 C 1 C, should
be at least a week. The milk may be
sour, have a bitter taste or a rancid
smell.
Processing and packaging under

poor hygienic conditions and/or
holding the packaged milk in warm
conditions. Provided the legal
temperatures of pasteurization have
been met the defect will have been
caused by post-pasteurization
contamination.
Warm conditions or absence of

refrigeration where milk is held.
Check all records of pasteurization

temperatures. Investigate all hygiene
practices. Carry out full visual inspection
and make bacteriological checks after
plant appears to be thoroughly cleaned
and disinfected. Check the temperatures
of the pasteurized milk from processing
through packaging to storage and
distribution. Rectify deficiencies in the
cold chain.
Cream plug
Presence of a thick cream layer in

pasteurized milk which may prevent the
milk from being poured from the bottle.
Free fat present in the cream layer
floats in droplets on the surface of hot
beverages such as coffee or tea.
Excessive pasteurization
temperature, double pasteurization,
excessive pumping, agitation and
aeration during handling, warm
conditions during distribution. The
most important factors are of a
mechanical nature which produce
turbulence in the milk and cause
disruption of the globule membrane
and churning.
Increased pasteurization
temperature and double
pasteurization destabilize the fat
globule membrane and increase its
sensitivity to mechanical forces.
There may be a seasonal variation in
the sensitivity of milk fat to
processing conditions.
Check on all stages where agitation of

milk applies. Reduce exposure of the
milk to physical forces, e.g. pumping,
vigorous agitation, aeration. Maintain
consistently cool.
Feathering
Formation of an unpleasant curd when

the pasteurized milk is added to hot
coffee.
Exact mechanism is not properly

understood. May be due to
precipitation of destabilized milk
protein by the acidic coffee solution.
Occurs more readily when milk is

kept hot by the consumer, caterer,
etc. Also occurs with homogenized
pasteurized milk.
Reduce time for which milk is held hot

prior to addition to coffee.
Stale flavour
Milk does not have its normal fresh

attractive flavour.
Thought to be due to a combination

of several minor changes such as
oxidation and lipolysis of the milk
fat and changes in the protein.
Stale flavours are often forerunners

to more serious off-flavours if
hygiene practices are not improved
or if milk is held for longer periods
before use.
Avoid conditions which lead to lipolysis,

etc. Practise strict hygiene measures.
Store milk at low temperature.
Oxidized or
sunlight flavour
Burnt or burnt-feather off-flavours.
Exposure of milk to sunlight or

artificial light
Milk is affected by light to varying

degrees when packaging in glass,
plastics, cardboard or foil laminate.
Avoidance depends on use of opaque

packaging materials such as board and
laminates.
BS 7771:1994
49
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by the consumer
Cause
Oxidized flavour The flavour of the milk is affected

leading to the consumer describing it as
cardboardy, tallowy, metallic, fishy or
oily.
Oxidation of some fatty acids

dependent on a catalyst.
Lipolytic flavour Rancid off-flavour developing in

(rancidity)
pasteurized milk after several days at
refrigerator temperature.
May be present in pasteurized milk

from fat-splitting enzymes produced
by bacteria destroyed by the
pasteurization process or by
contamination of the pasteurized
milk from plant surfaces.
Flavours
The normal attractive milk flavour is
described as
altered.
cowy, weedy,
feedy.
Unclean or
bitter flavour
Bitter and putrid flavours developing in

cold-stored milk after about 7 days after
pasteurization.
TCP
The pasteurized milk has a taste which
(trichlorophenol) is reminiscent of TCP antiseptic.
taint
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Common name
of defect
conditions
Was more common when copper

(a catalyst for the reaction) was
present in dairy equipment.
Catalysing copper-containing
residues may be present in cleaning
and disinfecting solutions. Iron may
also act as a catalyst.
Ensure that pasteurizing and packaging

plant is free from metallic residues which
may accumulate in plate packs. Make
certain that there are no copper or iron
surfaces in contact with milk. Check that
there are no residues of cleaning
materials in plate pack.
Practise strict hygiene. If milk is to be
held raw for any length of time before
pasteurization cool the raw milk to
around 3 C to 4 C to reduce bacterial
growth.
Most likely to be significant in the

milk from one herd which has access
to sources of strong-smelling
materials, feeds, weeds, etc. which
are transferred to the milk.
Avoid the cows having access to feed

materials or weeds having strong
smelling properties.
Proteolytic enzymes produced by

cold-tolerant bacterial contaminants
either before or after pasteurization
may form bitter peptides from milk
proteins.
Does not usually occur in

refrigerated pasteurized milk until
around 1 week after pasteurization
but depends on level of
contamination.
Check hygiene practices.
The off-flavour is produced by the

formation of chlorophenol
compounds from the interaction of
chlorine in water supplies or in
residues of chlorine-based
disinfectants or iodine from
disinfectants with phenolic
substances from disinfectants,
veterinary preparations, weed
killers and some plastics.
The amount of each compound,

i.e. chlorine and chlorophenol, which
can combine to produce a taint is so
small as to be undetectable
individually in normal
circumstances. One of the most
common causes of the taint is the
use of chlorine-containing
disinfectants with non-food-grade
plastics, e.g. piping.
Taste incoming supplies of milk (see note

to 5.4.3) and samples of pasteurized
milk. Reject any milk with a detectable
TCP flavour. Ensure that non-food-grade
plastics are not present or permitted in
the dairy premises.
BS 7771:1994
50
Common name
of defect

by the consumer
Cause
conditions
Extraneous
water
If severe, the consumer may consider

the milk thin and watery.
The farm and dairy may each be

sources of extraneous water gaining
access to milk.
The adulteration of milk with water

is an offence and care should be
taken to ensure that extraneous
water does not enter the milk
accidentally.
Ensure complete drainage of all

pipelines, tanks, etc. to avoid rinse water
or condensed steam gaining access to the
milk. Avoid careless flushing of milk
from the pasteurizer. Consult the
equipment supplier on the capacity of
pasteurizer and associated pipelines so
that sufficient water-contaminated milk
is taken off from the pasteurized supply
to the finished milk tank. The first milk
through packaging equipment should be
checked for normal freezing point and if
tests indicate that water is present in the
packaged milk reject until satisfactory.
Check for perforated heat exchange
plates.
Poor cream line
The consumer judges that a reduced

cream line indicates low fat level in the
bottled milk.
Processing factors such as agitation,

clarification, pumping and
pasteurization temperature may
affect the creaming process. The
cream layer volume is decreased by
heating milk at temperatures
above 73 C and becomes almost
non-existent after milk is exposed
to 82 C.
Non-homogenized milk develops a

cream line on standing. During the
creaming process fat globules
aggregate and rise to the surface.
Avoid temperatures which reduce cream

layer volume if this is of importance.
BS 7771:1994
51
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BS 7771:1994
Section 10. Plant maintenance and inspection

10.1 General
The milk processor is required to produce a
pasteurized milk which meets all of the statutory
requirements of this type of milk. These are
particularly designed to ensure safety of the product
to the consumer. From a commercial point of view
the milk processing company wishes to ensure that
all aspects of product quality are controlled and
quality is of a high standard in the product.
The efficiency of the milk processing operations
depends on a variety of factors, some of which are
labour related and others which are dependent on
the operational efficiency of equipment used in the
pasteurization and related handling, packaging,
storage and distribution activities.
It is essential that pasteurizing equipment is
operated to its design characteristics and is
maintained in accordance with the instructions and
suggestions of the equipment supplier.
Regular and systematic programmes of inspection
and maintenance by management, production and
engineering staff, and laboratory staff should be
designed for the individual dairy. The
representative of the equipment supplier should be
involved at an early stage since installations are
likely to vary and the individual technical features
of the installation can have a vital bearing on
ensuring safe and efficient operations. If, for
inspection and maintenance, persons are required
to climb on to machinery such as tanks or to
examine pipework at heights, safe means of access
should be provided. The power source of machinery,
whether electric, pneumatic, hydraulic or other,
should be isolated before access is gained to
normally dangerous moving parts of machinery.
Permit-to-work procedures should be instituted if
appropriate.
A systematic maintenance programme should be
brought into effect during the commissioning stage
of the installation and be agreed by the companys
technical staff and those of the supplier.
52
While the extent and sophistication of the

maintenance programme will depend on the
pasteurizing capacity and extent of automation of
the pasteurizing plant and ancillary equipment and
on the staffing arrangements at the dairy, the need
for a systematic programme extends over the
various sizes of operations.
The details of maintenance programmes including
action information should be properly kept and
available to appropriate persons within the dairy.
The dairy company and equipment supplier should
determine which aspects of maintenance should be
undertaken by their respective organizations.
Small dairy companies which include those with
pasteurizing plant rated to about 5 000 l/h or
producer processors may decide to arrange for the
more difficult items of maintenance to be contracted
out to a supplier or specialist company.
10.2 Inspection of equipment and

premises
10.2.1 General inspection
A daily check should be made by the production staff
and laboratory personnel, working in close
cooperation, of plant operation records, temperature
recorder charts and quality test results.
Any abnormalities should be reported immediately
to a technical manager.
In small plants and in farm dairy situations one
person may have responsibility for all or most of the
processing operations. Despite the fact that one
person is responsible for different aspects of the
operations it is important that a proper procedure
be established and used for checks on these items.
It is advisable that at least two people in a dairy be
thoroughly conversant with and skilled in operating
and cleansing and inspecting milk pasteurizing and
packaging equipment.
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BS 7771:1994
The premises used for milk processing equipment

should be inspected daily for cleanliness and
general hygiene. It is vital that staff develop and
maintain a strong commitment to personal hygiene
and cleanliness within dairy premises.
The general appearance of the processing
equipment and processing rooms should be pleasing
and should demonstrate attention to hygiene.
All areas of the processing premises, that is, the
exterior of processing plant and ancillaries, the
floors, walls and ceilings of the premises, should be
included in daily inspections.
Inspection of all areas of the premises should be
undertaken daily to ensure that vermin are being
controlled effectively. Milk pasteurizing companies
may enter into contracts with specialist vermin
control firms as a means of obtaining systematic
control over all forms of vermin.
10.2.2 Process and engineering inspection
recommendations
These are summarized in Table 6.
10.2.3 Service contract inspection
Operators of milk pasteurizing plants are
recommended to enter into an annual service
contract arrangement with a reputable dairy
engineering company to undertake the inspections
detailed in 10.3, and propose an appropriate repair
programme.
The general location of these items is indicated in
Figure 1 and Figure 8(a) and Figure 8(b).
10.3 Items to be inspected and/or

recorded
10.3.1 Instruments and flow diversion valve
assembly
NOTE
See encircled area in Figure 8(a).
The following should be inspected and/or recorded.

a) Instrument type.
b) Accuracy of hot pen.
c) Accuracy of cold pen.
d) Are the chart traces achieved satisfactorily?
e) Comparison of reference and hot milk check
thermometer.
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f) Event pen operation.

g) Is diversion set point accurate?
h) Condition of air supply.
i) Are air pressures correct?
j) Is the auto/manual switch functioning
satisfactorily?
k) Are all alarms functional?
l) Is the electric wiring in good order and are the
connections secure?
m) Is the interior of the instrument panel in a
clean and dry condition?
n) Does the flow diversion valve operate
efficiently?
o) Date when diaphragm previously changed.
p) Is the action of the flow diversion valves
positive?
q) Are all seals in good condition?
r) When were the air-operated valve cylinders
last overhauled?
s) Are all connections secure?
t) Any other observations.
10.3.2 Flow controller
NOTE
See encircled area in Figure 8(b).

a) Is the plant rate correct?
b) Are the spindle/disc and piston in good order?
c) Are the screens in satisfactory condition?
d) Is the unit operating freely?
10.3.3 Milk and hot water pumps
NOTE

a) Milk pump serial number.
b) External condition of pump.
c) Condition of the body interior.
d) Are the impeller holes clear?
e) Is the impeller rotating in the correct direction?
f) Condition of impeller/stub shaft driving faces.
g) Condition of the front seal.
h) Condition of the steel or ceramic running face.
53
BS 7771:1994
i) Condition of the water-cooled seal.

j) Is the water seal cooling device working
satisfactorily?
k) Is the water-cooled seal device correctly
positioned?
l) Condition of the back plate.
m) Is the stub shaft secure on the motor shaft?
n) Is the stub shaft correctly positioned?
o) Condition of the body clamp.
p) Is there any evidence of corrosion of the pump?
q) Is the motor operating at an acceptable
temperature?
r) Are the feed conditions satisfactory?
s) Any other observations.
10.3.4 Balance tank
NOTE

a) Condition of the inlet valve equipment.
b) Is the float in sound condition?
c) Does the balance tank show signs of corrosion?
10.3.5 Heat exchanger
NOTE

a) Machine type and number.
b) Plate arrangement drawing number.
c) Condition of the frame and tightening gear.
d) Minimum plate dimensions.
e) Actual platage dimensions.
f) Type of gaskets.
g) Condition and age of the gaskets.
h) Evidence of plate damage caused by corrosion,
etc.
i) Plate sequence as compared to the plate
arrangement drawing.
54
j) Condition of the grids, bosses, drain and vent

plugs.
k) Cleaning efficiency.
l) Retarder section or holding tubes.
m) Condition of the hanging eyes.
n) Alignment of the plates viewed externally.
o) Condition of press, gauges, thermometers,
valves, etc.
p) Are the pipe-hanging supports in good order?
q) Is the ratchet spanner operating satisfactorily?
r) Are there sufficient union spanners available?
10.3.6 Hot water set
NOTE

a) Are all connections secure?
b) Condition of the inlet tubes.
c) Condition of the instrumentation.
d) Is the hot water circulation correct?
e) Condition of the steam diaphragm valve.
f) Condition of the pressure-relief valve.
g) Condition of the steam-reducing valve.
h) Condition of the pressure gauges.
i) Boiler pressure.
j) Reduced steam pressure.
10.3.7 Milk filter
a) Condition of the filter-valve screens, seals,
vents, etc.
b) How often are the filter cloths changed?
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Possible defect/arm of inspection
General advice
Frequency of
inspection
Inspection made by
External surfaces of all items of

milk reception, storage,
pasteurization, packaging
installation.
Leaks from pumps, valves, pipelines, etc.
Daily
Competent dairy staff.
Milk storage tanks:
To ensure
Weekly
Normal working condition. No leakage. Float in

good order. No debris which would affect milk
pump.
Weekly
milk pump;
No leakage from pump shaft seal or pipeline

joint rubbers.
Weekly
flow controller.
Valve piston, spindle, valve button. On

re-assembly valve should be checked for free
and smooth movement.
Daily
agitator and timing

mechanisms;
valves;
spray balls.
Milk pasteurizer installation:
valve controlled balance
tank;
equipment working as required to ensure

thorough mixing of milk;
no leakage;
no blockages which would limit sprays.
Heat exchanger-plate pack
Corrosion of plate surfaces leading to leakage.

Deterioration of plate gaskets resulting in
leakage. Presence of debris trapped at plate
contact points especially in plate passes prior to
the filters. Effectiveness of cleaning and
formation of scale.
Plate packs have different tightening

requirements. In order to avoid damage
to gaskets follow manufacturers
instructions concerning opening and
tightening plate pack.
Monthly
Competent dairy staff plus

specialist service engineer if in
doubt.
Flow diversion valve
Valve springs and associated moving parts

should be inspected for damage and should be
serviced and lubricated. Motor diaphragms,
valve seats, rubbers, seals should be replaced at
first sign of deterioration.
All parts should be checked and found to

be in good order to prevent forward
seepage of milk when plate is in the
diverted state.
Annually

doubt.
Milk filter
Incorrectly fitted filter cloth
Fit filter cloths with nap or woolly

surface exposed to milk flow.
Daily
Hot water set
Controlling water to pasteurizing section of the

plate pack at required temperature.
Three-monthly
Valves and pipelines
All valves and pipelines inspected for

deterioration leading to leaks.
Monthly
Worn or defective components should be

replaced on a regular basis.
BS 7771:1994
55
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Plant item and component
BSI 06-1999
Possible defect/aim of inspection
Pressure gauges
Checked to see that indicating pointer zeros

correctly and that movement is smooth. No
moisture in instrument casing.
Indicating thermometers
General advice
Give valuable guidance to plant
performance by indicating changes in
general balance of flow throughout the
system.
Frequency of
inspection
Inspection made by
Daily
Competent dairy staff. Specialist

service engineer if in doubt.
Checked for accuracy against a thermometer of

known accuracy in the laboratory. Correction
tags should be dated and attached to the
machine. The thermometer indicating
pasteurizing temperature in the holder section
is critical because of statutory requirements.
Thermometer at the cold milk outlet of the plant
is also very important because of cooling
requirements. Thermometers indicating hot
water temperature and cooling medium
temperature provide information on plant
performance and any abnormalities to it.
Weekly
Recorders and controllers
Instruments should be kept clean, dry, dust and

oil free. Air supplies should be clean, dry and oil
free at correct supply pressure. Diaphragm
control valves should be regularly serviced.
Daily

specialist service engineer.
Service steam
Steam lines should be free from leaks and in

general good order and effectively lagged.
Inspection should include steam-reducing
valves, steam traps, strainers, stop valves,
control valves, steam and water mixers.
Three-monthly

doubt.
Water
Taps and valves should be free from leaks. In

Advice of water treatments specialists
hard water areas plant surfaces should be
should be sought.
examined for build up of scale. Soft water
supplies may be corrosive. pH of chilled water,
used as a secondary refrigerant, should be
checked to ensure that it is not too low. It should
be at pH 10 or slightly above.
Weekly

doubt.
Refrigeration plant
To check for normal operating conditions and

production of coolants at correct temperatures
Daily

specialist refrigeration engineer
if in doubt.
Calcium chloride brine
pH should be controlled between 8.5 and 9.0 to

minimize risk of corrosion.
Weekly
Poor process temperature control may be

due to inadequate regulation and control
of steam
BS 7771:1994
56
Possible defect/aim of inspection
Air
Regular inspection and care of air pressure

reducing valves, air filters, traps. Quality of air
is very important for operation of much of the
dairys equipment.
Electricity supply and electricity

operated equipment
Should be checked regularly for safety. Faults or

damage should be reported immediately for
action.
Milk packaging equipment
To ensure efficient operations, correct filling

levels and freedom from faulty closure of packs.
General advice
Instruments and controllers require
clean, dry, oil-free air; it is preferable to
have a separate compressor for
instrumentation. Many air-operated
valves and pneumatically operated
materials handling equipment require
lubricated air. Advice should be sought
from equipment suppliers on inspection
and maintenance.
Attention is drawn to statutory

requirements on filling levels.
Frequency of
inspection
Inspection made by
Weekly

doubt.
Three-monthly
Competent electrician.
Daily
BS 7771:1994
57
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BS 7771:1994
58
Figure 8(a) Service contract inspection. Location of plant items
59

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BS 7771:1994
Figure 8(b) Service contract inspection. Location of plant items
BS 7771:1994
Section 11. Cleaning and disinfecting milk

pasteurizing equipment and ancillaries
11.1 General
The following edited extracts from BS 5305:1984
describe the cleaning and disinfection of the
following equipment:
a) pumps and pipelines;
b) storage and transport tanks;
c) heat exchangers: batch type (holder) plants;
d) heat exchangers: continuous flow;
e) cotton filter cloths;
f) separators;
g) homogenizers;
h) water softeners;
i) bottle-washing machines;
j) milk bottles;
k) milk bottle crates;
l) container-filling machines.
Cleaning operations should follow a strict routine,
At the end of the milk run, pass cold water through
the whole plant to remove milk residues.
In 11.2 to 11.12, detailed recommendations are
given for the cleaning of individual pieces of plant
and equipment. Whilst the practice of cleaning
in-place is widely used and is applied to as much
dairy equipment as possible, the need for the
periodic manual cleaning of such equipment
remains. Isolate the power source and completely
dismantle equipment periodically and carry out the
methods of cleaning described in 11.2.3. If cleaning
and disinfecting require persons to climb on to
machinery such as tanks or to examine pipework at
heights, safe means of access should be provided.
It should be borne in mind that there is no single
detergent suitable for all cleaning in-place purposes
and, in selecting a detergent, attention should be
given to the fact that the soil to be removed from a
heated surface is of a different nature from, and
more tenacious than, that on an unheated surface.
The construction of certain items of plant is such
that they are prone to corrosion, e.g. crevice
corrosion and, whilst approved chemical
disinfecting agents may be used, at their
recommended concentration, with relative safety in
tanks and pipelines, corrosion may occur in some
items such as in plate-type heat exchangers and
drain cocks; for these items disinfection using steam
or hot water is recommended.
60
Chemical disinfecting agents are normally used at

low concentration and scale or protein residues
remaining in the equipment can deactivate the
disinfecting agent and seriously impair its
disinfecting efficiency. If residues or scale are
present, a disinfecting agent is effective only when
penetration occurs. Normal soaking or circulation
conditions are not effective when scale is present
and the residues can act, therefore, as a source of
bacterial recontamination. Adequate cleaning prior
to disinfection is, therefore, essential.
11.2 Pumps and pipelines

11.2.1 General
Pumps and pipelines may be disinfected after
previous cleaning or, if a cleaning in-place system is
in use, by cleaning and disinfecting in one operation.
11.2.2 Cleaning in-place systems
Use the following procedures.
a) At the end of the milk run, pass cold water
through the pumps and pipelines, in a similar
manner to the milk, to remove all loose milk
residues. During this procedure slacken the
retaining rings of the milk cocks and open
butterfly valves or lift the plugs so that the
component parts are thoroughly rinsed.
b) Because the design of plug cocks makes them
impossible to clean in-place they should be
dismantled, brushed thoroughly in detergent or
detergent/disinfectant solution, rinsed and
replaced.
c) Circulate a solution of a suitable
general-purpose detergent or approved
detergent/disinfectant. The temperature and
contact time will depend upon the product used.
A solution at 55 C to 60 C will usually
need 20 min of circulation at a speed of 1.6 m/s. If
a detergent/disinfectant is used, slacken the
retaining rings of all milk cocks to allow some of
the solution to escape via the well. Flush the
pipes with clean water, lifting the plugs as before
to ensure adequate rinsing. If a
detergent/disinfectant has been used, no other
treatment is necessary. If a detergent only has
been used, disinfect the equipment using one of
the following procedures.
1) Hot water. Circulate hot water through the
inter-connected pipework, fittings, etc., for a
period of not less than 20 min measured from
the time that all parts of the circuit reach a
temperature of not less than 80 C.
BSI 06-1999
BS 7771:1994
2) Chemical disinfecting agent. Circulate a

solution of a disinfecting agent (see 8.4.2.3).
Discharge to waste and rinse residues of
disinfecting agent from the equipment using
cold clean water and use immediately; if this
is not possible, re-disinfect immediately prior
to use.
11.3 Storage and transport tanks

11.3.1 General
Storage and transport tanks may be cleaned and
disinfected using either manual or cleaning in-place
techniques.
11.3.2 Cleaning
NOTE A solution of sodium hypochlorite containing 50 mg/l

to 100 mg/l of available chlorine used at ambient temperature
and a contact period of 10 min to 20 min is suitable.
11.3.2.1 Manual cleaning
11.2.3 Manual cleaning
The size of large tanks makes it necessary for the

operator to enter the tank when it is being cleaned.
Before entering the tank the operator should don a
pair of clean rubber boots, which are kept solely for
this purpose, and any other protective clothing
normally worn in such operations.
Periodically dismantle the pumps, pipelines and

other equipment for thorough cleaning and
examination.
a) Rinse as described in 11.2.2 a), dismantle and
then place in a trough containing a solution of a
general-purpose detergent. The trough should be
of sufficient length and depth to allow the pipes to
be completely submerged in the detergent
solution.
b) Brush all milk contact surfaces; for pipes use a
long-handled brush of minimum length slightly
more than half that of the longest pipe so that the
complete length can be cleaned by approaching, if
necessary, from both ends. The brush head
should be of the same diameter as, or a little
larger than, the bore of the pipe being cleaned. All
equipment should be colour coded to distinguish
between raw and pasteurized milk.
c) Rinse all parts with clean water.
d) Place the pipes on a clean rack to await
reassembly, and not on the dairy floor. A suitable
rack mounted on wheels is convenient, as it can
be used for collecting the pipes, etc., while
dismantling and for conveying them after
cleaning, during reassembly.
If it is possible to form the pipework into a closed
circulation circuit, disinfect by using one of the
procedures described in 11.2.2. If this is not
possible, disinfect dismantled pipelines and fittings
by using steam for a period of 15 min (see 8.4.2.2) or
by soaking them in a solution of disinfecting agent
[see note to 11.2.2 c) 2)] followed by draining and
rinsing the residues of disinfecting agent from the
equipment using cold clean water. Reassemble the
equipment immediately, taking precautions to avoid
recontamination. Use the equipment immediately;
if this is not possible, re-disinfect immediately
before use.
BSI 06-1999
11.3.2.1.1 General
11.3.2.1.2 Stainless steel tanks

Use the following procedure.
a) Thoroughly rinse the internal surfaces of the
tank with cold water. If necessary, scrub the
surfaces with a suitable long-handled nylon
brush.
b) Thoroughly scrub the internal surfaces of the
tank with a solution of a general-purpose
detergent or detergent/disinfectant suitable for
hand use, paying special attention to the inlets,
outlets, gaskets, air vents, propeller shafts and
any other fittings the tank may contain. Do not
use abrasives. Remove and dismantle the fittings
each time the tank is cleaned.
c) Thoroughly flush the tank with clean water to
remove all traces of detergent, leaving it ready for
disinfection (see 11.3.3).
11.3.2.1.3 Aluminium tanks
Use special detergents suitable for use with
aluminium, but in the same manner as for stainless
steel tanks.
11.3.2.1.4 Non-metallic tanks
Use detergents as recommended by the
manufacturers.
11.3.2.2 Cleaning in-place
11.3.2.2.1 General
Cleaning in-place of milk storage tanks and
transport vessels can be effectively undertaken only
if the vessel and its fittings have been correctly
designed and equipped for this type of cleaning.
61
BS 7771:1994
Very precise location of the spray device in relation

to the vessel and its fittings is essential if all
surfaces are to be effectively cleaned and
disinfected.
Individual spray devices may encompass a wide
variety of designs, each having a different optimum
mounting point within the vessel, widely varying
feed pressure requirements and differing flow
characteristics and spray patterns.
It is essential, therefore, that the advice of
equipment manufacturers is sought and that the
spray device is carefully matched to the cleaning
solution delivery pump and to the actual storage
vessel being cleaned.
A fine wire mesh filter should be fitted in the
detergent supply line prior to the spray device in
order to safeguard against blockage of any of the
spray orifices or nozzles by debris which could alter
the spray pattern within the vessel, leaving sections
of the surface inadequately treated.
11.3.2.2.2 Combined cleaning and disinfection
a) Rinse with water to waste until all loose milk
residues are removed.
b) Circulate a freshly prepared approved
detergent/disinfectant solution for the time and
at the temperature recommended by the
manufacturer.
c) Finally, rinse with cold clean water.
11.3.2.2.3 Separate cleaning and disinfection
Follow the cleaning procedure as described
in 11.3.2.2.2 using a detergent appropriate to the
materials of construction of the tank and specifically
formulated for cleaning in-place duties.
Recovery and reuse, following any necessary
readjustment of the detergent strength, may be
considered where separate cleaning and disinfection
is employed but is generally inadvisable with
combined detergent/disinfectants due to the
differing rates of exhaustion of the active
ingredients.
After detergent cleaning and rinsing with cold water
the tanks are ready for disinfection.
NOTE 1 If hot solutions are used in cleaning in-place systems
and especially if these are followed by cold water rinsing, care
should be taken to ensure that the tank is adequately vented,
e.g. by opening the manway cover or door, since any rapid
reduction in pressure within the vessel may result in collapse of
the tank walls. If vents are built into tanks it has been calculated
that a 14 000 l tank requires a vent of minimum
diameter 130 mm or equivalent area to cope with the possible
pressure changes whilst a 45 000 l silo requires a 350 mm vent
under similar operating conditions.
NOTE 2 The importance of pre-rinsing cannot be over
emphasized, particularly where combined
detergents/disinfectants are being used.
62
Pre-rinsing by means of a number of short bursts as

opposed to continuous rinsing will assist in the
dispersion and removal of milk froth which may
otherwise be inclined to float as rinse water builds
up in the tank outlet and will at the same time
result in economies of water usage.
11.3.3 Disinfection
Chemical disinfecting agents are more commonly
used. Where spray ball or other types of device are
used it is essential that they are correctly sited to
ensure that all internal surfaces are thoroughly
wetted by the solution of disinfecting agent.
Clean the tanks using the procedure recommended
in 11.3.2. If a detergent/disinfectant solution has
been used for cleaning, further disinfection is not
necessary if the tanks are used immediately. If the
tanks have been cleaned only, or have not been used
for 4 h or more, disinfect immediately prior to use as
follows.
a) Stainless steel tanks. Disinfect by using one of
the following three procedures.
1) If automatic cleaning equipment is
installed, spray a solution of disinfecting agent
(see 8.4.2.3) into the tank through the spray
ball or other type of distributing device. Rinse
the tank with cold clean water.
to 100 mg/l of available chlorine used at a temperature from
ambient to not greater than 40 C for a contact period of 10
min to 20 min is suitable.
2) Fog with a disinfecting agent. Site the fog

gun at the manway door and introduce the
solution of disinfecting agent at the
concentration and under the conditions
recommended by the manufacturer of the fog
gun. Rinse the tank with cold clean water.
3) On tanks suitable for steam disinfection,
introduce steam at a convenient point and
allow the condensate to run to waste. Continue
steaming for a period of at least 15 min after
the condensate has reached a temperature
of 85 C. Legislation in Northern Ireland
requires that in steam disinfection the
continuous period of 15 min is timed from
when the condensate has reached a
temperature of not less than 93 C. Ensure
that all vents are open during the subsequent
cooling-down period.
BSI 06-1999
BS 7771:1994
b) Aluminium tanks. Disinfect separately after

cleaning or clean and disinfect in one operation
by using one of the following procedures.
1) Disinfection. Clean the tank by using the
procedure described in 11.3.2.1.2 or 11.3.2.1.3.
Disinfect by spraying the surfaces with a
solution of a QAC (see 8.4.2.3 b). Rinse all
residues of the QAC from the tank with cold
clean water, after the contact time
recommended by the chemical supplier.
2) Combined cleaning and disinfection. Clean
and disinfect the tank using the procedure
described in 11.3.2.1.2 and 11.3.2.1.3 using a
solution of detergent/disinfectant suitable for
use with aluminium tanks (see 8.4.2.3). Rinse
the residues of solution from the tank with cold
clean water.
NOTE QAC is not an approved bactericidal agent in
Scotland.
3) Non-metallic tanks. The chemical and heat

resistance of non-metallic tanks varies widely
with the material of construction. The advice of
the tank manufacturer on the recommended
procedure for disinfection should always be
sought.
NOTE Attention is drawn to the need for periodic manual
cleaning of any equipment which is cleaned by in-place systems.
See 11.3.2.1.
11.4 Heat exchangers: holder (batch)

plants
11.4.1 General
Holder (batch) plants consist essentially of a
hot-water jacketed heating and holding tank, an
external-surface capillary cooler or plate-type
cooler, and auxiliary tanks, pipework and pumps.
They should be cleaned by the procedure described
in 11.4.2 and then disinfected by the procedure
described in 11.4.3.
11.4.2 Cleaning
a) Partly fill the holding tank with cold or warm
(40 C to 50 C) water and pump through the
complete system to remove milk residues. Rinse
the receiving tank (if used).
b) Partly fill the holding tank with a solution of a
general-purpose detergent at about 45 C and
scrub the internal surfaces, including auxiliary
fittings, with a suitable brush. Rinse with cold
clean water.
BSI 06-1999
c) Dismantle the receiving tank (if used), pumps,

milk cocks and piping and deal with them as
described in 11.2.3. Rinse with cold clean water.
d) Reassemble the equipment for disinfection
(see 11.4.3).
11.4.3 Disinfection
After the equipment has been cleaned and
reassembled (see 11.4.2), disinfect using the
following procedure.
a) In the holding tank prepare a solution of
disinfecting agent (see 8.4.2.3). Scrub the walls
using a long-handled brush; ensure that all
internal surfaces are thoroughly wetted.
b) For open-type coolers, pump the solution of
disinfecting agent in the holding tank over the
cooler and scrub the surfaces on both sides with a
suitable brush.
c) For plate-type coolers, proceed as described
in 11.5.3.2.
d) Discharge this solution of disinfecting agent to
waste, rinse the residues from the equipment
with cold clean water and use immediately; if this
is not possible re-disinfect immediately before
use.
11.5 Heat exchangers: continuous flow

plants
11.5.1 General
Carry out the cleaning of the heat exchangers in
accordance with the manufacturers instructions.
Typical instructions for the cleaning of HTST
exchangers are given in 11.5.3.
All sampling and drain cocks (if fitted) should be
removed daily for cleaning.
Temperature-recording charts should be in position
for the whole of the cleaning cycle as well as the milk
production run.
Disinfect the plant immediately prior to a
processing run; this is particularly important if the
plant has not been opened and inspected
immediately after the cleaning operation to ensure
that soil residues, from which bacterial
recontamination may occur, are absent.
Chemical disinfection is effective only when soil
residues are entirely absent; if there is doubt as to
the level of cleanliness achieved during cleaning,
disinfection using hot water should be used.
63
BS 7771:1994
11.5.2 Manual cleansing

11.5.2.1 General
In most instances, facilities for circulating detergent
solution through the equipment on a closed loop
system will be available. Where such facilities are
not provided it will be necessary to manually clean
the heat exchanger.
11.5.2.2 Cleaning
The plant should be cleaned at the end of each milk
run using the following procedure.
a) At the close of the milk run, shut off all
unwanted services. Displace milk from the plant
by running cold water through and continue until
the effluent water runs clear.
b) If a brine section is incorporated, remove brine
residues by thorough flushing with cold water.
c) Ensure that the heat exchanger is cooled to
ambient temperature and, if not, continue
passing water through until the machine reaches
a temperature not exceeding 30 C.
d) Open the machine by the procedure
recommended by the manufacturer taking
particular care to avoid damage to the plates and
to avoid displacing the gasket from the groove.
e) Manually clean all product plates using a
suitable detergent and a soft nylon brush taking
particular care to avoid displacing the rubber
gaskets from the gasket grooves. The detergent
solution should be made up in hot water and used
at as high a temperature as is practicable but not
less than 45 C. Follow the suppliers instructions
regarding the use of the detergent materials and
necessary safety precautions.
f) Hose off each plate with cold clean water.
g) Reassemble the machine following the
manufacturers recommendations regarding the
correct sequencing of the plates, method of
tightening and closure pitch.
If facilities permit, disinfect the equipment by one of
the methods described for HTST plants in 11.5.3.
11.5.3 HTST plant
11.5.3.1 Cleaning
The plant should be cleaned at the end of each milk
run using the following procedure.
64
a) At the close of the milk run shut off all the

unwanted services. Displace the milk from the
plant by running cold water into the balance tank
and, when cleared, return the flow to the balance
tank. Ensure that the exit line from the tank is
fully covered to avoid cavitation in the circulating
pump. Continue circulation for a period of not less
than 10 min.
b) In some cases it is necessary to slacken the
heat exchanger until it leaks slightly, although
this is regarded as unnecessary by many
equipment manufacturers.
c) If the circulating water is seriously
contaminated with milk residues, pump to waste
and refill the system with water. Introduce
detergent into the balance tank and circulate
within a closed circuit at 70 C to 80 C for 20 min
at a rate of flow at least 10 % more than that of
the milk. After long milk runs it may be necessary
to increase the concentration of detergent and the
time and temperature of cleaning. During the
circulation period, divert the plant several times
or alternatively at the end of the circulation
period reduce the temperature of the cleaning
solution and allow the plant to go into automatic
diversion for a period of 5 min. Brush the surfaces
of the balance tank above the detergent level, and
the lid, during circulation.
d) Flush the detergent solution from the heat
exchanger by pumping cold water through the
system. Unless soft water is used, cool the
detergent solution to 40 C before flushing out.
When necessary, the heat exchanger may then be
opened up, the plates brushed down and finally
hosed with cold clean water ready for reassembly
and disinfection (see 11.5.3.2). This is only
necessary infrequently. In some cases, the plant
manufacturer recommends that the exchanger
should be opened only by his agents.
NOTE Methods are available for cleaning heat exchangers by
means of which the plates may be cleaned and maintained bright
and scale-free without brushing and without opening the
machine. Such methods rely on the circulation of neutral and
alkaline solutions of polyphosphates and other calcium and
magnesium sequestering agents such as EDTA and its salts, and
sodium gluconate and heptonate. Accumulations of milkstone
may render an occasional acid descale advisable. The technique
recommended in such cases is described in 29.4 of BS 5305:1984,
and should be applied after the detergent circulation. However,
with the detergent formulations currently available acid
descaling should be unnecessary and, if a build-up of milkstone
occurs, consideration should be given to the use of an alternative
detergent system.
BSI 06-1999
BS 7771:1994
It is strongly recommended that, after an acid

descaling wash has been given and the acid flushed
out with water, a final weak alkaline solution,
equivalent to a 0.1 % (m/m) solution of sodium
hydroxide, should be circulated to ensure that,
should dilute sodium hypochlorite solutions be used
after cleaning to disinfect the plant, the solution
remains alkaline (a pH of 9) and therefore much less
dangerous to stainless steel than a solution of the
same available chlorine content but with its pH
reduced to, e.g. 6 by accidental acid admixture.
After cleaning the plant by using the procedure
described in 11.5.3.1, disinfect it by using one of the
following procedures.
a) Hot water. Circulate hot water through the
equipment for a period of not less than 15 min
measured from the time that all sections of the
plant reach a temperature of not less than 80 C
(see 8.4.2.2). Operate the flow diversion valve
frequently throughout the circulation period in
order to disinfect this section of the plant.
b) Chemical disinfecting agent. Circulate a
solution of disinfecting agent (8.4.2.3). Discharge
to waste and rinse residues of disinfecting agent
from the equipment using cold clean water and
use immediately; if this is not possible,
re-disinfect immediately prior to use.
NOTE 1 Many chemical disinfecting agents are potentially
corrosive to plant and equipment especially at elevated
temperatures. In order to minimize the risk of corrosion, ensure
that the plant is cold and that all steam valves are closed before
introducing the solution of disinfecting agents.
NOTE 2 It is essential that the rate of circulation is sufficient
to ensure the complete displacement of air from the equipment
and the thorough wetting of all surfaces.
NOTE 3 A solution of sodium hypochlorite conforming to the
following is a suitable disinfecting agent:
1) available chlorine content of 50 mg/l to 100 mg/l;
2) contact time of 10 min to 20 min;
3) temperature not greater than 40 C.
11.6 Cotton filter cloths

11.6.1 General
Dirty filter cloths should be cleaned by the
procedure described in 11.6.2 or 11.6.3 and then
disinfected by the procedure described in 11.6.4.
New filter cloths should be washed prior to use to
remove textile dressing and then disinfected by the
procedure described in 11.6.4.
BSI 06-1999
11.6.2 Manual cleaning

a) Place the dirty filter cloths on a clean flat
surface away from the processing equipment;
hose hard to wash off loosely adhering soil or
rinse thoroughly in several changes of hot water.
Cloths should not be brushed as this will weaken
the fabric, reducing the useful life of the cloth.
b) Wash the cloths in a hot solution of a detergent
suitable for textiles. Do not use strong-smelling
soaps such as carbolic. If required, a few drops of
sodium hypochlorite solution in the wash water
will act as a bleach, removing unsightly stains.
c) Completely remove the detergent from the
cloths by two rinses in hot water, followed by two
rinses in cold water.
d) Carefully squeeze the cloths and dry them
prior to disinfection (see 11.6.4). Inspect cloths
against a good light and do not reuse if any
thinness of the fabric, wear or damage is evident
in any part of the cloth.
11.6.3 Machine cleaning
After hosing the dirty filter cloths, they may be
washed in a small domestic machine using a
detergent solution suitable for textiles at 60 C
to 70 C. After thorough rinsing they should be
dried, inspected as given in 11.6.2 d) and prepared
for disinfection (see 11.6.4).
11.6.4 Disinfection
It is essential to disinfect washed filter cloths before
reuse. Steam disinfection is recommended as dry
heat or chemical methods will cause rapid
deterioration of the fabric.
Fold cloths to a convenient size and pack them in a
reclosable metal drum or wrap individually in
greaseproof paper. Disinfect in an autoclave or a
steam chest. In an autoclave, cloths should be
subjected to a temperature of 104 C or above
for 20 min: in a steam chest, the temperature
should be 93 C or above for 30 min. Temperatures
achieved may be checked by placing
temperature-sensitive indicator paper within the
mass of cloths prior to treatment.
Filter cloths should not be disinfected in-place
during the disinfection of plate heat exchangers
[see 11.5.3.2 a) and b)] but should be fitted to the
filter carriers immediately prior to the
commencement of product processing and included
in any hot water pre sanitization treatment.
65
BS 7771:1994
11.7 Separators
11.8 Homogenizers
11.7.1 Cleaning
11.8.1 General

a) At the close of the run, flush with water
at 40 C to 50 C until the water runs clear.
Dismantle and remove bowl and discs.
b) Scrub small parts, bowls and discs, using a
mild alkaline detergent solution at 40 C to 50 C.
Hold the discs between the revolving brushes of a
manually-operated disc scrubbing machine, or
scrub them in a suitable tank reserved for this
purpose.
Alternatively, an automatic disc-washer may be
used, when the detergent can either be of higher
alkalinity than that used for manual cleaning, or
as recommended by the disc-washer
manufacturer. Follow the manufacturers
recommendations with regard to temperature
and cleaning. If milkstone has developed follow
the recommendations of 8.3.3.
c) Flush the detergent solution away with cold
clean water.
d) Reassemble the separator, which is then ready
for disinfection.
Three methods may be used for cleaning and

disinfecting homogenizers. The homogenizer may be
disassembled and cleaned manually, treated as a
separate unit or cleaned in place with the main
HTST plant. Whilst the materials of construction
used in homogenizers will generally be unaffected
by alkaline detergent solutions, due to the use of
high strength stainless steels in some units, care
has to be exercised in the use of acids and the advice
of the equipment manufacturer should be sought.
Milk residues in homogenizers have a high chloride
content which, by interaction with acids, can give
rise to serious corrosion of certain materials.
Extreme care should be taken to ensure that the
detergent solutions are free from undissolved
particles which may cause damage to the piston
seals and homogenizing valves.
11.7.2 Self-cleaning separators

Follow the manufacturers instructions. A detergent
of the type used for cleaning evaporators is
generally suitable.
11.7.3 Disinfection
Clean separators by using the procedure described
in 11.6.1 and after reassembly connect to the
plate-type heat exchanger and disinfect by
circulating hot water (see 8.4.2.2) or by circulating a
solution of QAC (see 8.4.2.3). Drain the equipment
and rinse residues of QAC solution from the
equipment using cold clean water.
NOTE Chemical disinfecting agents other than QACs may be
suitable but the advice of the equipment manufacturer should be
sought.
66
11.8.2 Cleaning
11.8.2.1 Manual cleaning
a) At the end of the milk run, unload
homogenizing valves and rinse out with water to
remove the loose milk residues. Allow the rinse
water to go to waste.
b) Remove associated pipework and clean as
outlined in 11.2.
c) Remove pressure gauges, top caps, front caps,
valves, springs, packing assemblies and similar
components.
NOTE It is essential to exercise extreme care when handling
the components to avoid damaging them, especially sealing
faces and pistons. The homogenizing valves may be
manufactured from extremely hard material which, if
dropped on to a concrete or tiled floor, could crack. Individual
components should never be put into a cleaning trough or
bucket but should be laid out on a mat on a trolley or table,
each part separated from the others and grouped into the sets
of components for each cylinder so that each part is
reassembled into its original location in the homogenizer
block, thus minimizing the wear on valve seatings, etc.
BSI 06-1999
BS 7771:1994
A separate identifying mark on each of the

components for each individual cylinder, e.g. by
number stamping on a non-bearing part of the
surface of each component when the machine is
first commissioned, will further assist in
ensuring that all parts are regularly
reassembled in their original locations.
d) Manually clean the individual components
using a suitable hand-washing detergent based
on sodium silicate/sodium phosphate used at a
concentration of 1 % (m/m) to 2 % (m/m) or a
suitable combined detergent/disinfectant and at
as high a temperature as possible but not less
than 45 C. The bores and channels in the
cylinder block should be thoroughly cleaned free
of milk residues with the detergent solution using
a suitable nylon or bristle brush.
e) Thoroughly rinse each component with clean
water.
f) Before reassembly, carefully inspect each
component for cracks, mechanical damage or
excessive wear and replace if necessary.
g) If milkstone deposits are apparent and not
removed by the detergent solution, the individual
components should be immersed in a 0.5 % (V/V)
to 1 % (V/V) solution of phosphoric or nitric acid
made up in a suitable container. Allow the
components to stand in the acid for 15 min
to 30 min, remove and thoroughly rinse with cold
clean water.
h) Reassemble the homogenizer in strict
accordance with the manufacturers
recommendations, using torque wrenches if
specified.
i) Disinfect by the procedure given in 11.8.3.
11.8.2.2 Separate cleaning in-place
Use the following procedure if the homogenizer is
being cleaned as an individual unit, without
complete disassembly.
a) At the end of the milk run, unload the
homogenizing valves, shut off the drive motor
and drain the homogenizer.
b) Connect the homogenizer and associated
pipework to form a closed circuit incorporating a
detergent reservoir that has an indirect heating
facility and is of a suitable size.
c) Start up the homogenizer and rinse out with
hot water, running the water to waste, until the
unit and pipework are cleared of milk residues.
Return the outlet to the reservoir tank and fill to
a suitable level.
BSI 06-1999
d) Add sufficient detergent of the type used on the

main plant or any specified product for cleaning
homogenizers to the reservoir and run the
homogenizer and associated pipework on a closed
loop. The detergent temperature and the
circulation time should be in accordance with the
manufacturers recommendations. Apply a
pressure of about 550 kN/m2.
e) Pump the detergent to waste and flush with
cold clean water. If soft water is not used, cool the
detergent to at least 40 C before flushing.
f) If recommended by the manufacturer, remove
pressure gauges, homogenizing valves and any
stand pipe pressure pulsation damper, inspect
and, if necessary, manually clean and rinse
(see 11.8.2.1). Reassemble for disinfection
(see 11.8.3).
NOTE 1 In pre-rinsing and final rinsing the time of circulation
should be kept to a minimum owing to the poor lubrication
properties of water on the piston rods and bores. No special
precautions other than those mentioned are necessary when
alkaline detergents are used, as these provide adequate
lubrication.
NOTE 2 On certain duties it may be necessary to incorporate an
occasional acid circulation in the cleaning regime. This should be
undertaken after step f) and either 1 % (V/V) phosphoric
or 0.5 % (V/V) nitric acid solution employed. It is essential that
all acid residues are thoroughly rinsed from the circuit by
flushing the equipment with cold clean water.
11.8.2.3 Cleaning in-place

If a homogenizer is to be cleaned as part of a full
processing circuit, a by-pass should be fitted in order
that the necessary plant flow rate for cleaning the
plant can be achieved. It will also be necessary to
unload the homogenizing valves to
approximately 550 kN/m2.
Proceed with rinsing and detergent circulation as
appropriate for the duty on which the homogenizer
has been used and as described in 29.4 of
BS 5305:1984.
After completion of the cleaning run, if
recommended by the manufacturer, remove
pressure gauges, homogenizing valves and stand
pipe pressure pulsation dampers, inspect and, if
necessary, clean manually by the procedure
outlined in 11.8.2.1, thoroughly rinse and
reassemble.
Disinfect by the procedure described in 11.8.3.
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BS 7771:1994
11.8.3 Disinfection
11.10 Bottle-washing machines
Homogenizers can be disinfected in conjunction

with processing plant or separately within their own
closed circuit. Because of potential corrosion
hazards great care should be taken in the choice and
use of chemical disinfecting agents. Disinfection by
the use of hot water is the preferred method. Clean
the homogenizer by using one of the methods
described in 11.8.2. Release the pressure from the
homogenizing valves and introduce hot clean water.
Continue circulation for a period of not less
than 20 min after the return water has reached a
temperature of 80 C. Disinfection should be carried
out immediately before using the plant for
processing.
11.10.1 Cleansing
NOTE 1 Ensure that all drain valves, pressure gauge

connectors, pressure pulsation damping stand pipes etc., are
raised to a temperature of 85 C for not less than 15 min by
bleeding the lines throughout the disinfecting period.
NOTE 2 The large mass of metal in homogenizer blocks
necessitates a long heating-up period.
11.9 Water softeners

Base exchange water softeners may become
contaminated and so contaminate the dairy water
supply; in this event disinfect the softener by one of
the two following procedures according to the type of
exchange material which the softener contains.
a) Organic resin beds. Only formaldehyde-based
disinfecting agents are suitable. Prepare
a 1 % (V/V) solution of formaldehyde by
adding 300 ml of commercial formalin
solution (400 g/l formaldehyde in water)
to 12 l of water; add this 1 % (V/V) solution to the
resin bed in the softener and allow it to remain in
contact for a period of not less than 12 h. Then
rinse the bed with cold clean water for a period of
not less than 30 min and regenerate the bed
according to the manufacturers instructions.
b) Inorganic beds. Disinfect these older types of
exchange material either by using 1 % (V/V)
formaldehyde solution as described in item a) or
by using a solution of sodium
hypochlorite (500 mg/l of available chlorine),
prepared by adding 50 ml of hypochlorite to 10 l
of water, with a contact time of 18 h followed by
rinsing with cold clean water and regeneration
according to the manufacturers instructions.
68
Clean and disinfect daily the various parts and

sections of bottle-washing machines by using the
following procedure.
a) With a suitable brush, brush all jet manifolds
to remove deposits and check that the jets are
clear by using fine wire.
b) Remove overhead trays and brush thoroughly.
c) Replace jets and trays; steam and final rinse
the jets in place.
d) Empty warm recirculated rinse tanks and
brush out to remove all debris. Using a hosepipe,
rinse with cold clean water.
11.10.2 Recirculated rinse sections
Disinfect recirculated rinse sections by using one of
the following two procedures.
a) Fill the rinse tanks with cold clean water. Heat
the water to a temperature of not less than 85 C,
e.g. by injecting steam from a securely fixed
hosepipe. Circulate the hot water through the
pumps and jets for a period of not less
than 10 min.
NOTE Some rinse tanks are fitted with thermostats which
are not suitable for operation at a temperature of 85 C. In
such cases the advice of the manufacturer of the
bottle-washing machine should be sought before proceeding.
b) Fill the rinse tanks with cold clean water.

Add 250 ml of a solution of sodium hypochlorite
to 500 l of water to give a concentration
of 50 mg/l of available chlorine and circulate this
solution through the pumps, jets and overhead
trays for a period of 10 min. Drain the tanks and
rinse free from hypochlorite with cold clean
water.
NOTE 1 In order to reduce the possibility of corrosion of the
machine do not exceed the recommended concentration of
hypochlorite and the contact time.
NOTE 2 If the rinse section is badly scaled, disinfection by
hypochlorite solution may not be effective, adequate rinsing may
be impossible and corrosion of parts of the machine which are not
visible may occur owing to penetration of the hypochlorite
solution behind scaled areas.
BSI 06-1999
BS 7771:1994
11.11 Milk bottles
11.11.3 Detergent provisions
11.11.1 Statutory requirements
Under normal working conditions in a

bottle-washing machine, a good bottle-washing
detergent is expected to exhibit the following.
a) Good detergency, as evidenced by a very low
proportion of rejects or by some bottle staining
test, e.g. 5 % (V/V) carbolfuchsin in a 10 % (V/V)
ethanol/water mixture.
b) The ability to produce microbiological
acceptable bottles.
c) The ability to produce brilliant, non-steamy
and bloom-free bottles.
d) Minimal accentuation of scuffing damage.
e) The ability to maintain the washer in a clean
and scale-free condition.
f) The ability to lubricate moving parts which
pass through the detergent solution.
g) Minimal corrosive tendencies.
h) Extremely low-foaming properties; in some
cases, particularly in hydro machines,
anti-foaming properties will be required.
i) Relative economy.
In addition, it is expected that the detergent
solution will at all times:
1) have no pronounced odour which might linger
in the bottle;
2) be non-toxic in trace amounts.
Returned milk bottles have to be washed effectively

and disinfected before refilling with milk.
11.11.2 General observations
The efficiency of all automatic bottle-washing
machines depends on:
a) correct mechanical maintenance to ensure that
each bottle receives its full quota of treatment;
b) adequate pre-rinsing to prevent excessive
fouling of the detergent solution;
c) maintaining the detergent solution at the
correct temperature and concentration;
d) preventing recontamination of the bottles from
the rinses which follow the detergent treatment.
To maintain efficiency, completely change the
detergent solutions in all bottle-washing machines
at regular intervals. As a guide it is recommended
that the detergent should be discarded when its
sodium carbonate content exceeds 1 % (m/m). This
may need to be done more frequently during the
summer months. It is also recommended that all
tanks be thoroughly cleaned and hosed out when the
solution is changed. Keep filters and jets thoroughly
clean and under daily observation to ensure
operation at the maximum efficiency.
In addition to cleaning the bottles, the detergent
solution is relied upon to disinfect them.
Temperature, concentration, pH and period of
contact are all factors in the disinfecting power of
the detergent solution.
The period of contact is generally dictated by the
type of machine and accordingly only the
temperature and concentration are within the
control of the operator. Hold the temperature of the
detergent solution as high as possible, bearing in
mind the risk of damage to the bottle by thermal
shock. Regular titration or automatic metering to
gauge the concentration is essential, refresher
charges of the detergent being added as required. If
laboratory facilities are not available, regularly use
the testing equipment, which may be supplied by
the detergent manufacturer.
Provided the cleaning method is satisfactory, bottles
will be microbiologically acceptable when they leave
the detergent section. In order that subsequent
recontamination does not take place, clean and
disinfect the rinse sections of bottle-washers
regularly, preferably daily.
BSI 06-1999
11.11.4 Fully automatic bottle washing

11.11.4.1 Soaker hydro machines
The sequence of treatment in soaker hydro
machines varies widely. The treatments may,
however, be summarized as follows.
a) Pre-rinsing by jetting or soaking in water
at 35 C to 40 C.
b) Soaking, with or without jetting, in detergent
solution at 60 C to 80 C.
c) Rinsing by jetting with water at 40 C to 50 C.
d) Final jetting with clean water.
A caustic-based detergent is usually used at a free
sodium hydroxide concentration of
between 0.75 % (m/m) and 1.5 % (m/m).
69
BS 7771:1994
11.11.4.2 Hydro machines

The sequence of treatment is as follows.
a) Pre-rinsing with water at 35 C to 40 C.
b) Jetting with detergent solution at 60 C
to 80 C.
c) Rinsing by jetting with water at 40 C to 50 C.
d) Final jetting with clean water.
A caustic-based detergent is usually used at a
free sodium hydroxide concentration of
between 0.4 % (m/m) and 0.75 % (m/m).
11.11.5 Semi-automatic washing
The recommended steps in semi-automatic washing
are as follows.
a) Rinse the bottles in cold or warm (40 C
to 50 C) water to remove loose deposits or debris,
in order to avoid excessive fouling of the
detergent solution.
b) Jet or soak the bottles in a suitable
detergent/disinfectant solution at about 50 C.
Strongly alkaline detergents are not
recommended because of the risks to operators.
Weak alkalis are not effective disinfectants and it
is therefore recommended that an approved
combined detergent/disinfectant be used in
accordance with the manufacturers instructions.
c) After detergent/disinfectant treatment, rinse
the bottles by jetting with clean water.
11.11.6 Manual washing when chemical
disinfection is to be used
Use a detergent or detergent/disinfectant
recommended by the manufacturer for manual use.
The following treatment is recommended.
a) Rinse all bottles with water as soon as possible
after their return. Brush all dirty bottles
separately in a solution of a detergent or of a
detergent/disinfectant.
b) Soak the bottles for a minimum of 2 min in
either a solution of a detergent or an approved
detergent/disinfectant, at the concentration
recommended by the manufacturer, at 45 C
to 50 C. This preliminary treatment is
important in order to remove as much as possible
of the milk residues before the main treatment.
c) Brush the bottles in a freshly prepared solution
of an approved detergent/disinfectant or of a
detergent with an approved disinfecting agent at
the concentration and temperature recommended
by the manufacturer. Thoroughly clean and
disinfect all brushes after use.
d) Rinse with clean water and invert to drain in
clean crates (see 11.12).
70
11.11.7 Manual washing when disinfection by

steam is to be used
Use the detergent recommended by the
manufacturer for manual use.
The following treatment is recommended.
a) In order to avoid undue fouling of the detergent
solution, remove loose deposits or debris by
rinsing the bottles in cold or warm (40 C to 50 C)
water.
b) Brush the bottles, either manually or with
power-driven brushes, in a solution containing
the recommended amount of a general-purpose
detergent at 45 C to 50 C. Thoroughly clean and
disinfect all brushes after use.
c) Rinse the bottles in clean water, after which
they are ready for disinfection by steam in a
steam chest (see 17.5 of BS 5305:1984).
11.11.8 Treatment of very dirty milk bottles
The degree of soiling of dirty bottles returned to a
dairy varies considerably, but the combination of
detergent and washing treatment which a bottle
receives in a modern bottle-washer ensures that
usually only a very small percentage (usually less
than 0.005 %) require rejection on the grounds of
imperfect cleanliness.
Many rejected bottles re-passed through the washer
will emerge in a perfectly clean condition.
Bottles which are so grossly soiled that a
bottle-washing treatment cannot clean them should
be destroyed. Such bottles can usually be identified
before they enter the washer.
Where a special treatment can clean them the
following is recommended. Soak for a prolonged
period (overnight) in a strong [1 % (V/V)
to 2 % (V/V)] bottle-washing solution. Following
this, wash them manually, using a brush, in a
detergent solution at 45 C to 50 C suitable for
manual washing purposes and return to the usual
cleaning and disinfecting procedure.
11.12 Milk bottle crates

Maintain milk bottle crates in a clean condition and
wash each crate before it is reused.
The need for regular washing of milk bottle crates
made from plastics is stressed because of the
soil-attracting properties of the plastics materials
commonly in use.
If crates are washed in a spray-type tunnel washer,
satisfactory results are usually obtained from a
bottle-washer antistatic type of detergent.
If crates are washed manually, thoroughly scrub
them inside and out with a general-purpose
detergent suitable for manual use. After this
treatment rinse the crates with clean water.
BSI 06-1999
BS 7771:1994
11.13 Container-filling machines

11.13.1 General
Container-filling machines include bottle-filling and
carton-filling machines. In some cases, cleaning
involves dismantling all or part of the machine. In
order to avoid extensive dismantling, most
bottle-filling machines are now designed so that
cleaning in-place can be carried out as far as is
possible. This involves the circulation of water and
detergent solutions through the machine.
Container-filling machines may be cleaned
(see 11.13.2) and then disinfected (see 11.13.3) or
they may be cleaned and disinfected in one
operation (see 11.13.4).
11.13.2 Cleaning
11.13.2.1 Bottle-filling machines
11.13.2.1.1 Manual cleaning
a) Drain the filler bowl of milk and rinse with cold
water.
b) Dismantle all removable fittings, e.g. valves,
air pipes, star wheels, guide rails and filling
rubbers, and wash these separately with a
solution of a suitable detergent at 40 C to 50 C,
paying particular attention to the valve stems.
c) Scrub the filler bowl thoroughly with a solution
of a suitable detergent at about 50 C.
d) Immerse the parts of the filler valves in a
solution of an approved chemical disinfectant.
Reassemble and replace on the filler bowl, taking
care not to recontaminate the parts while doing
so and thoroughly scrub all parts in the solution
using appropriate brushes.
e) Rinse thoroughly with cold clean water to
remove all traces of detergent and reassemble the
machine. The assembled machine is now ready
for disinfection.
f) Clean and disinfect the cap-forming die and
sealing head of the machine, paying particular
attention to the forming die and sealing heat
rubbers. Carry out this process in accordance
with the manufacturers instructions.
g) Wash and disinfect the vacuum system daily.
11.13.2.1.2 Cleaning in-place
This procedure is unlikely to be used in the scale of
processing operations covered by this code of
practice. Unless specifically designed for cleaning
in-place, this procedure is not recommended. The
routine adopted will depend to some extent on the
construction of the machine, but the recommended
basic procedure is as follows.
BSI 06-1999
a) Drain the filler bowl of milk and depress the

float to its lowest level. Loosen all unions and
valves.
b) Connect the milk inlet pipe to a cold water
supply and disconnect the vacuum pipe. Set the
machine to run at its lowest speed throughout the
cleaning procedure. Flush with cold water until
the water coming out of the machine is clear and
free of milk residues. Run this water to waste.
c) Remove the start wheels, guide rails, plough
and filling rubbers, and clean these manually in
a solution of a suitable detergent at 40 C
to 50 C. Fit the surge cups.
d) Connect the milk inlet pipe to the tank
containing detergent solution at a temperature
not below 70 C. With the machine running,
circulate this solution through the machine
for 15 min to 20 min, returning it to the detergent
tank via the vacuum pipe. During this process,
detergent solution will escape from the loose
unions and valves and will clean the outside of
the machine.
e) Drain the machine of detergent solution. This
solution may be stored and reused if required. If
this is done, it is important that the strength of
the solution is regularly checked.
f) Connect the milk inlet pipe to a cold clean water
supply and, with the machine in motion, flush
until the water running to waste is free from
detergent residues. If alkaline detergents are
used, this can be determined by checking the
alkalinity of the waste water with a suitable
indicator.
g) Reassemble the dismantled parts of the
machine and ensure that all unions and valves
are tightened. The machine is now ready for
disinfection.
h) Clean the sealing or capping section of the
machine as described in 11.13.2.1.1 f).
11.13.2.2 Carton-filling machines
11.13.2.2.1 General
Many modern carton-filling machines are designed
and equipped for cleaning in-place. However, where
such facilities do not exist it will be necessary to
dismantle all removable parts and clean the
machine manually.
11.13.2.2.2 Manual cleaning types
In general, it is not possible to employ cleaning
in-place with these machines and cleaning involves
dismantling all removable parts and cleaning
manually.
71
BS 7771:1994
a) At the end of the filling period rinse through

with cold water, except in the case of cream,
when water at 40 C to 50 C should be used.
Wash away any product which has been rinsed on
to the tracks.
b) Dismantle removable parts.
c) If the machine has been used for filling milk
into cartons, rinse all components thoroughly
with cold water. In the case of machines used for
cream into cartons, rinse thoroughly with water
at 50 C.
d) Clean all components manually with a solution
of a suitable detergent at 40 C to 50 C.
e) Rinse all components thoroughly with cold
water until free from detergent.
f) Reassemble the machine, which is now ready
for disinfection.
In all cleaning operations involving filling
machines, bear in mind that the rubber components
present special problems, as they tend to absorb
milk fats. To extend the life of rubber components it
has been found advantageous to use alternate sets,
storing them under suitable conditions when not in
use, e.g. in solutions containing 5 % (m/m) of sodium
hydroxide.
NOTE Parts of the filler may become damaged if detergent or
disinfecting solutions are circulated through the reassembled
filler at temperatures above those recommended by the
manufacturer of the filler. In case of doubt the manufacturer
should be consulted.
11.13.2.2.3 Carton-filling machines designed and

equipped for cleaning in-place
Due to the wide range of types and designs of
carton-filling machines it is impossible to cover in
detail all the approaches currently available. The
manufacturers advice should always be followed in
such cases and detailed cleaning in-place
recommendations should always be sought from the
manufacturer when such machines are installed
and commissioned.
11.13.3 Disinfection
Clean the machine by using the procedure described
in 11.13.2 and disinfect by using one of the three
following procedures.
a) Chemical disinfecting agent. Fill the bowl of
the machine, preferably through the pipelines
which are used to pass the product to the filler,
with a solution of disinfecting agent (see 8.4.2.3).
Ensure that all internal surfaces are thoroughly
wetted with the solution and allow to stand for an
adequate period. Discharge the solution through
the bottle-filling heads ensuring that the surfaces
are thoroughly wetted. Rinse the equipment free
from residues of solution using cold clean water.
72

to 100 mg/l of available chlorine used at ambient temperature
for a contact period of not less than 10 min is suitable.
b) Hot water. Pass hot clean water through the

product feed pipeline to fill the bowl completely,
adjust the float control, if necessary, and
maintain this level throughout the disinfection
period. Discharge the water through the filler
valves and continue operating the machine for a
period of not less than 15 min measured from the
time the effluent water reaches a temperature
of 85 C (see 8.4.2.2).
c) Steam. Using a suitable connection, inject
steam into the filler through the product feed
pipeline. When all product contact surfaces reach
a temperature of 85 C continue steaming for a
further 10 min (see 8.4.2.2). Drain condensate
from the system via the filler valves. Reassemble
the machine by fitting the sterilized filler valve
cap sealing and filler head rubbers, taking
precautions to minimize recontamination of these
components.
NOTE 1 In all three procedures, disinfect filler valve rubbers
and sealing head rubbers separately by removing and immersing
them in a solution of disinfecting agent (see 8.4 and, in
particular, 8.4.2.3). A solution of approved sodium hypochlorite
containing 20 mg/l of available chlorine, prepared by added 1 ml
of hypochlorite to 5 l of water, used at ambient temperature for a
period of not less than 2 h is suitable. Rinse the rubbers in cold
clean water.
NOTE 2 The equipment should be used immediately after
disinfecting; if this is not possible, re-disinfect immediately
before use.
NOTE 3 Disinfection by using hot water or steam is not suitable
for all machines; before using either of these methods consult the
machine manufacturer.
11.13.4 Combined cleaning and disinfection

Clean and disinfect the machine by using the
procedure described in 11.13.2 with a solution of
detergent/disinfectant (see 8.4.2.3). Rinse residues
of solution from the machine with cold clean water.
See also notes to 11.13.3.
11.14 Management of cleaning and

disinfecting products
11.14.1 General
Because high standards of physical and
bacteriological cleanliness in the dairying industry
are essential, and cleaning and disinfecting
operations are an integral part of the production
line, successful management implies both close
attention to the training of operatives in the safe use
of detergents, detergent/disinfectants and
disinfecting agents, and continual supervision to
ensure that there is no deterioration in standards of
hygiene and safety.
BSI 06-1999
BS 7771:1994
When solutions are being prepared, the quantities

of water and detergents or chemical agents should
be measured carefully. Thermometers of known
accuracy should be used for checking the
temperatures of solutions and, in particular, the
temperatures at strategic points during heat
disinfecting procedures. Carelessness can result in
waste of detergents and chemical agents, ineffective
cleaning and disinfection or damage to plant and
personnel.
Solid detergents and detergent/disinfectants should
be stored in covered containers in a dry cool place;
liquids should be stored in the original containers
which should be kept closed. Solutions of
chlorine-releasing chemicals should be stored in a
cool place protected from light; it is not advisable to
carry large stocks in warm weather. Strict stock
control of all products should be exercised to avoid
deterioration and waste.
If chemical methods of disinfection are used, it is
essential to ensure that the solution of disinfecting
agent is in contact with all internal surfaces for the
required period of time.
In various clauses of this code of practice, reference
is made to the manual reassembly of equipment
after disinfection. The risks of recontamination
during such a procedure are self-evident and every
care should be taken to reduce such risks to a
minimum. The use of pre-sterilized disposable
plastics gloves or the wearing of disinfected rubber
gloves during such operations is strongly
recommended. Such disinfection can be effected and
maintained by frequent dipping of the gloved hands
into a solution of sodium hypochlorite maintained
at 50 mg/l to 100 mg/l of available chlorine. Parts
should be reassembled by taking them straight from
the disinfecting vessel to their location in the
equipment. They should never be placed on any
possibly unhygienic surface prior to reassembly.
BSI 06-1999
11.14.2 Hazards in transport and use of

chemicals used in cleaning and disinfecting
processes
Detergents, particularly those used in the more
difficult operations such as cleaning after heat
treatment, or in bottle washing, contain potentially
hazardous materials, as do some types of chemical
disinfecting agents.
Primary hazards arise during transport or use of the
material, and concern the effect of spillage of the
material on or near the person of the operator.
Suppliers should provide adequate warning of such
hazards, either incorporated in the general label on
the container or as a separate warning label.
Secondary hazards can arise from admixture of
incompatible materials or incorrect use of the
chemicals. While warnings of such hazards may be
included on the container label, it is wise to keep
such warnings clear, simple and relating to the
main hazard only. Suppliers therefore have the
alternatives of providing warning of these
secondary hazards on container labels, in technical
literature or by other means. Examples of such
warnings on labels are as follows.
a) Caustic liquid. Do not dispense using
aluminium or white-metal taps. Explosive gas
produced.
b) Acid-corrosive. Do not mix with any
chlorine-based material. Poisonous gas
produced.
c) Caustic powder. Causes burns. In case of
contact with skin wash immediately with
running water.
Attention is drawn to The Dairy Industry Code of
Practice for the Safe Storage, Handling and Use of
Chemical Substances, published by the National
Dairymens Association and available from National
Dairymens Association, 19 Cornwall Terrace,
London, NW1 4QP.
73
BS 7771:1994
Annex A (informative)
Legislation relating to milk products
and health and safety
A.1 UK legislation relating to milk and milk
products
Food Safety Act 1990. Chapter 16.
Food and Drugs (Scotland) Act 1956. Chapter 30
Food Safety (Northern Ireland) Order 1991.
The Food Safety (NI) Order 1991 (Consequential
Modifications) Order (NI) 1991. SR 1991:203
The Dairy Products (Hygiene) Regulations 1994.3)
The Dairy Products (Hygiene) (Scotland)
Regulations 1994.3)
The Dairy Products (Hygiene) Regulations
(Northern Ireland) 1994.3)
A.2 Relevant health and safety legislation
Health and Safety at Work etc. Act 1974
Factories Act 1961
Management of Health and Safety at Work
Regulations 1992
Workplace (Health, Safety and Welfare)
Regulations 1992
Provision and Use of Work Equipment
Regulations 1992
Manual Handling Operations Regulations 1992
Health and Safety (Display Screen Equipment)
Regulations 1992
Personal Protective Equipment at Work
Regulations 1992
Control of Substances Hazardous to Health
Regulations 1988 (COSHH)
Electricity at Work Regulations 1989
Noise at Work Regulations 1989
A.3 Other UK legislation
UK Water Supply (Water quality) Regulations 1989
A.4 EEC Directives
Council Directive 92/47/EEC Conditions for
granting temporary and limited derogations from
specific Community health rules on the production
and placing on the market of milk and milk-based
products.
Council Directive 92/46/EEC Health rules for the
production and placing on the market of raw milk,
heat-treated milk and milk-based products.
Council Directive 80/778/EEC Quality of water for
human consumption
3)
Council Directive 89/392/EEC Health and safety

requirements for design and construction of
machines
Council Directive 89/665/EEC Minimum health and
safety requirements for the use of work equipment
by workers at work
Council Regulation (EEC) 2377/90 Laying down a
Community procedure for the establishment of
maximum residue limits of veterinary medicinal
products in foodstuffs of animal origin
Council Regulation (EEC) 1411/71 Laying down
additional rules on the common market
organization on milk and milk products for drinking
milk
Annex B (informative)
Bibliography
IDF Standard 121 A:1987 Dairy plant-sampling and
inspection procedures for hygienic conditions.
Published by the International Dairy Federation,
Brussels.
IDF Bulletin No. 200/1986. Monograph on
pasteurized milk. Published by the International
Dairy Federation, Brussels.
Guidance notes on farm pasteurization. Published
by the Lancashire Association of Chief
Environmental Health Officers.
Guidelines for the good hygienic practice in the
manufacture of dairy based products. 1st Edition
December 1989. Published by the Dairy Trade
Federation.
APV Publication A278i. Milk pasteurization.
Published by the APV Company Ltd.
Notes for guidance on batch pasteurising plants for
milk. Published by the Scottish Office Agriculture
and Fisheries Department.
Notes for guidance on high temperature short time
(HTST) milk pasteurising plants. Published by the
Scottish Office Agriculture and Fisheries
Department.
Notes for guidance on the cleaning and disinfection
of ancillary equipment associated with milk
pasteurisers. Published by the Scottish Office
Agriculture and Fisheries Department.
In preparation.
74
BSI 06-1999
blank
75
BS 7771:1994
List of references (see clause 2)

Normative references
BSI publications
BRITISH STANDARDS INSTITUTION, London
BS 593:1989, Specification for laboratory thermometers.

BS 2690, Methods of testing water used in industry.
BS 2690-109:1984, Alkalinity, acidity, pH value and carbon dioxide.
BS 4285, Microbiological examination for dairy purposes.
BS 4285-1, Guide to general procedures.
BS 4285-1.1:1991, Sampling and preparation of samples.
BS 4285-3, Methods for detection and/or enumeration of specific groups of micro-organisms.
BS 4285-3.2:1991, Enumeration of thermoduric bacteria.
BS 4285-4:1991, Methods for assessment of hygienic conditions.
BS 5304:1988, Code of practice for safety of machinery.
BS 5305:1984, Code of practice for cleaning and disinfecting of plant and equipment used in the dairying
industry.
BS EN 294:1992, Safety of machinery Safety distances to prevent danger zones being reached by the upper
limbs.
Other references
Code of practice for the assessment of milk quality of the Joint Committee of Milk Marketing Boards of
England and Wales.
Reports on Public Health and Medical Subjects Drinking water supplies Methods for the examination
of water and associated material Report No. 71 The bacteriological examination of water supplies.
HMSO:1982
Joint Report of the Department of the Environment, Department of Health and Social Services and the
Public Health Laboratory Service.
Informative references
BSI publications
BRITISH STANDARDS INSTITUTION, London
BS 3095, Methods for the determination of the freezing-point depression of milk.

BS 3095-1, Methods.
BS 3095-1.1:1988, Thermistor cryoscope method.
BS 3095-1.2:1988, Hortvet method.
76
BSI 06-1999
BS 7771:1994
Other references
The Dairy Industry code of practice for the safe storage handling and use of chemical substances. Published
by the National Dairymens Association.
Guidelines for the sampling and testing of pasteurized milks for enforcement purposes (February 1989).
Published by the Association of Public Analysts, Dairy Trade Federation, Institution of Environmental
Health Officers, Milk Marketing Board of England and Wales, National Farmers Union, and the Public
Health Laboratory Service.
IDF Bulletin No. 292/1994. Recommendations for the hygienic manufacture of milk and milk-based
products. Published by the International Dairy Federation, Brussels.
IDF Document D 170:1988 Published by the International Dairy Federation. Brussels.
IDF Document D 222:1991 Published by the International Dairy Federation. Brussels.
IDF Standard 63:1971 Published by the International Dairy Federation. Brussels.
IDF Provisional Standard 82A:1987 Published by the International Dairy Federation. Brussels.
IDF Provisional Standard 155:1992 Published by the International Dairy Federation. Brussels.
Pasteurising Plant Manual, third edition, 1983. Published by the Society of Dairy Technology, 72 Ermine
Street, Huntingdon, Cambridgeshire PE18 6EZ4).
Codes of Practice on Machinery Safeguarding. Dairy Trade Federation.
4) Referred
to in the foreword only
BSI 06-1999
BS 7771:1994
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Licensed Copy: Oxford Brookes ATHENS, Oxford Brookes University, 27/07/2009 23:19, Uncontrolled Copy, (c) BSI

Code of practice for

Committees responsible for this

This British Standard, having

Amendments issued since publication

Fundamentals of the cleaning process

For the purposes of this British Standard, the

dairy premises used for the treatment, processing,

a dye reduction test which measures the extent of

a deposit that contains calcium caseinate and

a process that reduces the number of bacteria in

a method which determines whether or not milk has

1.4 International definitions

NOTE Pasteurization is intended to avoid public health

1.4.2 A pasteurized product

A negative phosphatase test is considered to be

Section 2. United Kingdom and European

2.2 The Dairy Product (Hygiene)

2.3 Council Regulation (EEC)

2.4 The Consolidated Food Labelling

2.5 Methods and conditions for milk

2.6 Statutory requirements

Table 1 Methods and conditions for milk pasteurization

UK legislation relating to pasteurized milk(s) prescribe the following:

Method and conditions of

Milk has to be pasteurized that is to say:

Cleaning and disinfection

Instruments and working equipment intended to come into direct contact

Milk storage and transport

The temperature at which pasteurized milk may be kept until it leaves

The pasteurized milk has to meet prescribed quality standards.

Packaging, sealing and

Bottling, filling of containers with heat-treated milk and the sealing of

A derogation may be granted to establishments with limited production.

Special dispensations may apply.

Raw milk for the

Raw milk for the

(if not collected

Plate count at 30 C k 100 000/ml

Geometric average over 2 months;

Somatic cell count

Geometric average over 3 months;

k 6 C if not treated As above

Plate count at 21 C < 50 000/ml (m)

Plate count at 30 C From 1.1.94 k 400 000/ml

Somatic cell count

From 1.1.98 k 100 000/ml

Legal quality standards

From 1.1.94 k 500 000/ml

Freezing Point Depression (FPD)

Legal quality standards

Cheese other than hard cheese

Milk-based products, other than

Milk products, other than milk

2.7 Documentation and records

Such records relate to the monitoring of the critical

2.8 Pasteurized semi-skimmed and

2.9 Pasteurized milk-based drink or

2.10 Health and safety

Employers should assess the risks, list significant

Table 3 Summary of statutory requirements for milk pasteurization

Food contact surfaces

Hazard analysis and critical