Guidance Material
for the development
of a
Food Safety Programme
(Food Act 1981)
for
Yoghurt Manufacture
ii
Contents
Contents ii
1.1 Purpose of this Document 1
1.2 Using this Document 1
2.4 Generic Process Description 2
2.5 Hazard Analysis and CCP Determination � Yoghurt 5
1
1.1 Purpose of this Document
The purpose of this document is to supplement information provided in the Interim
Code of Practice for Specialist Cheese and provide advice and guidance for the
manufacture and storage of yoghurt, in order to provide products that are safe to
consume.
The owner and sponsor of the Interim Code of Practice is the:
New Zealand Specialist Cheese Makers Association
P O Box 12092
Auckland
1.2 Using this Document
This document may be used in conjunction with the Interim Code of Practice for
Specialist Cheeses, to form the basis from which businesses can develop a Food
Safety Programme (FSP) for the production of yoghurt in New Zealand or for sale
in New Zealand and Australia.
To develop a FSP, obtain the Interim Code of Practice for Specialist Cheeses and
become familiar with its� contents. Using the Code, start at section 2.0,
�Components of a Food Safety Programme/Product Safety Programme� and work
through each section. Most sections will apply equally to cheese and yoghurt
manufacturer. Additional guidance for yoghurt manufacture is included in this
document, numbered according to the equivalent section in the Code.
The Code and this document will be used as the document against which a FSP for
yoghurt manufacture is audited.
The requirements comply with standards established in legislation, but are otherwise
ways by which industry has agreed as suitable for achieving (good/best practice)
effective control of food safety hazards.
2
A purpose of the Code is to make the implementation of a FSP easier. It does this
by:
� providing a format and information for hazard analysis and critical control
point identification that can be edited and used directly;
� providing information about supporting systems that state the outcomes
which need to be met, and where possible, providing examples of
procedures that can be edited and used directly;
� providing information that needs to be included and used directly; and
� providing examples of forms for record keeping that can be edited and used
directly.
2.4 Generic Process Description
The following flow chart is a broad description of the yoghurt making process;
covering all process steps.
At the FSP level, a detailed process description, specific to your business is needed.
This may be expressed as a flow chart or a written description.
3
Yoghurt Production Process Flow Chart
Day One
t
Filtration
Milk in Vat
Pasteurisation
Yoghurt Heat
Treatment
Heat Treatment
Coagulum
Break Up
Day Two
Option 1
Starter
Greek thickened
yoghurt
Straining into bags
Chilling
Chilling
Packing
Chill Storage
Liquid/stirred
yoghurt
Mixing
Thinning
Packing
Chill Storage
Sugar
Ingredients
(Optional)
Plastic bottles
[Sterilised]
pottles/lids
[Sterilised]
cotton Bags
Option 2
4
Notes:
1. Batch pasteuriser tank may be used for yoghurt heat treatment step
2. Yoghurt heat treatment is at 85�C for 30 minutes, or 95�C for 5
minutes or equivalent, then cooled to 38-40�C.
3. Starter added at 39-40�C, stirred in for 5 minutes
4. Coagulum break up should be 8 hours after starter edition
5. Ingredients optional except for sugar for liquid/stirred yoghurt
6. Chilling should be to ?4�C
7. Whey is output of straining yoghurt into bags
8. Greek yoghurt packed 24 hours after straining into bags
9. Preservatives added?
10. Final product at ?4�C shelf life @ 15-20 days
5
2.5 Hazard Analysis and CCP Determination � Yoghurt
Note:
1. Some of these processes may not be applicable to the individual yoghurt maker, and other steps may need to be
included.
2. If a process step has been identified but other columns are blank the process step is a �prompt�.
Raw material & other inputs
Q1. Is the hazard at unacceptable
levels?
Process step
Component Hazards
(B � biological
C � chemical
P � physical)
Process step hazards and/or
potential impact of process step
on existing hazards
Yes/No Justification
Q2. Control measure available?
B � Non-spore pathogens from
cow, e.g. Salmonella, Listeria,
E. coli, Mycobacterium bovis
(TB)
B � Similar pathogens from milk
handler, equipment, shed, pests
Yes
No
Some pathogens expected in
raw milk
Personal, equipment and shed
hygiene
Water quality programme
Pest management programme
See pasteurisation step for available
control measures
See supporting systems
Farm Dairy PSP
Microbiological tests (frequency?)
B � Spore forming pathogens
from cow, e.g. Clostridium
perfringens, Clostridium
botulinum
Yes Some spores expected in raw
milk
See steps for cheese processing for
control, e.g. acidification, aerobic
storage/temperature control
1. Farm dairy
collection (this
may be
included in the
farm PSP)
Raw milk
B � Mycotoxins from cow No Diet controlled Animal health programme
Farm Dairy PSP
6
Raw material & other inputs
Q1. Is the hazard at unacceptable
levels?
Process step
Component Hazards
(B � biological
C � chemical
P � physical)
Process step hazards and/or
potential impact of process step
on existing hazards
Yes/No Justification
Q2. Control measure available?
C � Chemical residues from
cow, e.g. antibiotics,
pesticides,
heavy metals
Yes
No
Untested milk
Tested milk � minimal residue
violations by national
monitoring programme
On-farm tests
Animal health programme
See testing programme for chemical
residues
C � Chemical residues from
cleaning: milk handler or
equipment, environment; Pests
No Cleaning programme
Chemical control
Personal hygiene
Pest management programme
See supporting systems
Farm Dairy PSP
P � jewellery, nail polish, bristles,
metal, rubber, plastic: milk
handler, equipment, environment
No Personal hygiene
Maintenance programme
On line filter plus maintenance
Supporting systems
2. Chilled
storage of milk
Mixed storage
Raw milk B � Increase in pathogens in raw