This section will cover HACCP engineering and maintenance

Figure 1. Layout of facility

Zoning: Separation of high/low risk areas

Milk arriving at the top right, continues along our process becoming a finished packaged product
ready for distribution. The reversed/docked truck (below our raw milk arrival) shows we’ve
planned significant factory floor between the arrival and packaging areas.

Design, Installation and Maintenance

Containers the raw milk arrive in are of stainless steel ISO standard as are the vats, coolers and
storage containers (ISO 2037:1992). Maintenance of refrigeration systems, water pumps, heat
treatment and packaging equipment is performed as per manufacturing guidance.

Of the above mentioned equipment, regular technical calibrations are performed. Each done
routinely, eg. ‘Appendix 1’. showing the refrigeration quality control document.
Standard maintenance of services of water, ventilation, pest control have been developed by an
external competence - EcoLab Inc. Details of which are mentioned next.

Pest Control
Our internal and external environment is compliant with pest control standards. Outside, the
surrounding grassland is regularly maintained as well as the immediate walls of the main
processing unit being checked for nested rodents. Vent exits are finely meshed to prevent live
entry. Electric controls are in place to kill airborne insects and floor rodents. With a notifying
noise, in the presence of floor trap kill. In this event, remediative action is taken to investigate
potential area of entry.In this event, no product leaves the facility and EcoLab are requested to
visit. QA begins at each stage of production, testing parameters for contamination.

Plant and Equipment: Cleaning and Sanitation standard maintenance.

Personnel hygiene measures, gloves, hairnet, soft mouth mask and shoe covers to be worn in
high risk areas. Maintaining the full integrity of the equipment used, is done with daily cleans,
some parts of equipment requiring dismantling, see Appendix 2, 3.
For deep cleans, a process was designed to reduce potential errors - a container was made so
each part during dismantle had a place, after washing, thus all parts were seen to be present or
not. All chemicals used are compliant with safety data sheets.

Waste Management
In the event of spoilage our product may need to be disposed of through a lawful method of
dairy waste practice. As of, I could only find UK laws stating a proper disposal of dairy for
businesses. Feedback from from FSAI would be needed.

Appendix 1. Fridge QC, daily check.

2. Quarterly Hygiene Rota ( Sample documents and records from I.S. 340:2007)
3. Weekly Hygiene Record