Quality Control Dairy Lactovita

Quality Control of Dairy Product

Quality Control of Dairy product

Prepared by

Manager-Quality Control, Dairy

Manual on QC of Dairy product of 33


Part - A



01. Introduction of Quality Control of Dairy product:

This work manual/ instruction provides information required toconduct organolyptic, Physical, chemical, and microbiological testof raw milk, pasteurized milk and other milk products. It isdesigned in such a way that one can do the testing of milk and milkproducts easily when required. This enables one also to prepare andstandardize the different chemical reagent required. Thisinstruction will help the individuals to build confidence in themregarding the various testing of milk.

02. Objective:

Milk is highly quick perishable product. It has to be handled withcare so that its properties may not go beyond control duringprocessing. To get good products keeping its physiochemicalproperties within control, one has to have sufficient knowledge asto milk and milk products. It is a little endeavour to provide asmuch ideas/ knowledge through this book let as is required toindividual.

03. Collection of milk from milk collector / supplier:

3.1 Milk Collection Procedure:



In collection centre lab technician has to take the sample fromthe milk pot through agitating. Milk will be accepted ifthe milk shows the good result during checking followingphysical quality parameter.

Collection people will take the milk from the supplier minimum100 litre. During collection respective staff will fill upthe checklist and write actual quality and quantity in thesupplier book and company’s book. After taking the milk it willchill immediately up to 0-40 c and then loaded into theinsulated tanker at the same temperature.

After loading the milk collection people will take the sampleagain and test the milk in respect to average fat, CLR & Temp.,and write a challan for factory. They will keep the samemilk sample until getting the result from factory. Than theywill be sealed the cover of milk tanker and will be lockedproperly to prevent any unwanted circumstances.

Vehicle driver will take the sealed challan copy and will bestarted to the factory. Vehicle driver should careful duringdrive the loaded tanker. Tanker should run through the levelroad because the maximum shaking of milk the fat will beseparated on the top layer and the temperature may beincreased.

04. Collection of Raw Milk from Milk Tanker:

For producing of milk products, respective QC people start theiractivities with a sample collection of milk. For this process theymaintain the following process.



Procedures:

Washed the milk preserver tanker with sprayed water to removedirt of the outer surface

Check the security seal of the tanker by the respective QCpeople

Collection of milk (250 ml) in a clean and dry beaker

Check temperature of the sample milk and record accordingly.

Milk should be agitated with a plunger for at least fiveminutes.

Check bacteriological test of collection milk (500 ml) with aclean & dry beaker

Sample milk should be kept in laboratory for other test

Stored the milk below 4oC

Important Notice to be remembered for sample collection

For getting better and accurate result sample of milk should becollected in a proper way. Necessary tests (Physiochemical andmicrobiological tests) are to be completed in a specific instructedmanner. The following points to be remembered while collecting thesample.

o The containers used for sample must be dry & sterilized.

o Microbiological test must be required for sample.

o Sample should represent the whole mass

o Proper agitation is a must inside the tank while sampling

o Collected sample will be tested as early as possible. If itis too late to test, it needs to be stored below 4oC.

o Apron, cap, and hand gloves to be dressed in whileperforming microbiological test. wear



o Outlet of pipes must be sterilized while collecting sample.

05. Quality Control test for collected sample milk: Sample is tested by two ways:

Organoleptic test:

Test of sample is to be executed with different organs like eyes,mouth, nose and hands by the selected personnel. Colour, Texture andFlavour and smell. These have some specific criteria that mustconform to the standards.

SL Item oftest

Standard Result

01.

Colour Generally white, creamy white. Color ofskim milk is greenish- white.

02.

Texture Natural milk has free flowing properties

03.

Flavour Normal milk possesses pleasant flavor I,e, combination of sweet flavor oflactose and salty flavor of minerals

04.

Smell

Physical and Chemical tests for milk:

SL Item oftest

Testing procedures Result

01. Alcoholtest orAPT test

Instruments: Test tube, pipette

Chemical Reagents: 75% Ethyl alcohol(75ml. of 100% alcohol + 25ml. distilledwater)

Procedure: Take 1 ml. milk in a test tubeand add 1 ml. alcohol and mix well.

Observation: If milk clots or flakeManual on QC of Dairy product of 33


appears the test is (+) ve. Reject themilk. If (–) ve receive milk

02. Colt-on-Boiling(COB)Test

Instruments: Test tube, pipette, spiritlamp

Procedure: Take 5ml. milk in a test tubeand boil.

Observation: If milk clots or flakeappears the test is (+) ve. Reject themilk. If (–) ve receive milk

03. AcidityTest(TitratableAcidityTA)

Instrument: Conical flask, burette,pipette

Chemical Reagent: 0.1(N) NaOH solution,1% phenolphthalein indicator

Procedure: Take 9ml. milk in a conicalflask add some water and few drops ofphenolphthalein. Titrate drop by dropwith 0.1 (N) NaOH solutions from burette.When permanent light pink colorappears, stop titration. Take the burettereading and divide by 10 to get theacidity of milk.

Preparation of 0.1 (N) NaOH solutions:Take 4 gm. of pure NaOH (AnalyticalGrade) in a 1 liter volumetric flask. Addlittle distilled water and shake well todissolve NaOH. Now add more water andfill upto the mark.

Preparation of 1% phenolphthalein: Add 1gm. phenolphthalein in 100ml. methylatedspirit and shake well.

04. PH Test Instrument: Beaker, Thermometer, PH meter

Chemical Reagent: Standard buffer Soln

(PH = 7.0±.02)



Procedure: a) PH meter calibration: Take 100ml freshbuffer solution of 7.0 PH into beaker at20oC temp. and submerse the electrode ofPH meter into buffer solution. If PH

meter gives reading 7 then it isunderstood that PH meter is in rightoperational position. If the reading 7 isnot shown then PH meter is not in rightoperational position. In that casenecessary correction in PH meter is to bedone. For necessary correction requiredinstructions are given in PH metercatalogue.

b) Take about 200ml milk in to a beakerand submerse electrode of PH meter intobeaker. The reading shown by PH meter isthe PH of the milk sample.

05. Fat TestCLR Test

Instruments: Butyrometer (with cork),auto burette of H2SO4, auto burette ofamyl alcohol, milk pipette, centrifugemachine.

Chemical reagent: 92 % H2SO4 , 100 % amylalcohol.

Procedure: Bring the temp. of milk up to300 C. Take 10 ml 92 % H2SO4 from autoburette into the butyrometer .Pour exact10.94ml milk in to butyrometer with milkpipette in such a way that the layer ofmilk remains separately from H2SO4. Take1 ml amyl alcohol from auto burette intothe butyrometer. Fixt the cork into thebutyrometer and shake the butyrometercautiously to mix the whole mass properly.Put the butyrometer into the centrifugemachine in a position opposite to eachother. Here it is to be mentioned that atleast two butyrometer should be taken attime. Centrifuge the machine for at leastfive minutes. Take out butyrometer fromcentrifuge machine. Take the reading by



coinciding the lower meniscus of fat withzero reading of butyrometer.

06. CLR Test Instrument: 200 ml. measuring cylinder,lactometer, thermometer.

Procedure: Bring the temperature of themilk at 29 0 C. Pour in the cylinder andput the lactometer in the milk. Read thelactometer reading.

07 SNFCalculation (SolidNon Fat).

After getting fat percentage reading &corrected lactometer reading, than SNF iscalculated as below

SNF Calculation = CLR / 4 + % of Fat / 5+ 0.14.

When all tests both physical & chemical ofmilk sample have been carried out, QCpeoples display the test results on thedisplaying board.On the basis of QC tests results, productionpeople starts their functioning with rawmilk.

In addition to the above test someadulteration test of milk is done to ensurethe quality of milk.

Some times farmers use soda, formalin,hydrogen per oxide etc to prevent milk fromspoilage. In addition to these, some timesfarmers uses starchy material to increasethe lactometer reading/ or add vegetable fatto skimmed milk for getting more fat.

08. Soda identification Test

Instruments: Test tubes, pipettes,volumetric flask.

Chemicals: Rosalic acid, alcohol

Procedure: At the end of the alcohol testdescribed earlier, to it, add one drop ortwo rosalic acid and shake.



Observation:If milk turns to red pink thensoda is positive i,e, soda is present in themilk and if color id brown then sada isnegative i,e, soda is absent in the milk.

09. Formalinidentificationtest

Instruments: Pipettes, test tubes, testtube holder, spirit lamp, pipette filleretc.

Chemicals : Hydrochloric acid ( 37 %),Ferric Chloride 1 %.

Procedure: Take 5 ml raw milk and 2.5ml hydrochloric acid in a test tube . Add2 to 3 drops of ferric chloride to it andheat the solution slowly.

Observation: If solution takes violetcolor than formalin is positive i,eformaline is present.



10. Hydrogen Peroxide identification test.

Instruments: Test Tube, Pipette 1 ml.

Chemicals: Potassium Iodide soln . 5 %,starch soln 2%, conc. hydrochloric acid

Procedure: Take 10 ml milk in a testtube. To it add 1 ml potassium iodidesoln and 1 ml starch soln and shakewell.10 ml conc. hydrochloric acid isthen added to it and keep test tube inrest . If the color is blue ,thenhydrogen per oxide is positive i,e,hydrogen peroxide is present .

11. Sugaridentificationtest

Instruments: Beaker, pipette (10 ml) , spatula. Paper.Chemicals: Resorcinol.Procedure: Take 15 ml milk ,to it add 1ml hydrochloric acid and 0.1 gm resorcinol. Keep the mixture for five minutes on the boiling water bath. Observation: Red Color indicates presenceof sugar i,e sugar is positive

12. Brix Test Instruments: Refractometer.

Procedure :

Calibration of refraction : Take water of onedrop or two in the dried lenses ofrefractometer. Adjust the lower level ofthe shade with zero by looking throughthe hole in the back of refractometer .Refractometer is now calibrated.

Wipe the refractometer to dryness withabsorbent (tissue paper, bloting paperetc.) and take one or two drops of sampleto be tested in the lenses ofrefractometr. Take the reading countingup from zero to the number with which theupper level of the shade coincides bylooking through the back hole. Say, theupper level of the shade coincides with



17.5 number. The brix of the sample is17.5 0 Be.The tests results are displayed in the displaying board.

13. MethyleneBlue ReductionTest (MBR):

To have the ideas of the population ofmicroorganisms in the milk, MethyleneBlue Reduction (MBR) test iscarried .Removal of methylene blue coloris directly related with population oforganism. If the color goes away quickly,the number of organism is more. If goesslowly and takes more time, then numberof organism is less. On the basis of timerequired for removing color, milk isgraded

06.Quality Control test parameter of raw milk:

Some of the parameters are tested to maintain accepted range. Thistest result is very important for milk to reduce losses of milk.Test results are to be kept in file (maintain log sheet) for futurereference.

Serial No.

Testing Parameter AcceptedRange

Remarks

01. Alcohol Test (68 & 72 % ) -Ve02. COB Test -Ve03. Acidity 0.11—0.17 %04. PH 6.6—6.805. Fat 3.0—6.0 %06. CLR 25—28 %07. SNF 7—9 % %08. Colour White09. Temperature 2OC—10OC10. Flavour Good



07. Observation during cream separation:

Production people have to separate excess cream from the milk (ifrequired) after unloading milk from tanker. During the separation ofcream from milk, QC people have to observe it closely and collectsamples (cream and skimmed milk) for test. The test results aredisplayed in the board.

08. Observation during mixing of ingredients:

Recipe of fresh and flavoured milk (Mango and Chocolate milk) is tobe prepared as per the instruction of SOP. During mixing of batchpreparation QC people has to ensure that the amount of ingredientsis OK and it has to standardize as per our requirement. In thisstage necessary tests have to complete as mentioned earlier. Duringmanufacturing these (Mango flavoured and Chocolate flavoured) milk,Brix is the unit of measuring sugar concentration has to be checked

Part - B



CIP

The summery of CIP is tabulated in following table.

Sl. CIP Step Time (Min.) Temperature Concentrati Remarks



No ( O C ) on

( % )01. Cold water

rinsing5 -- ----

02. Hot water rinsing

5 –10 60—70 ----

03. Caustic solution

20-25 75—80 1.75—2.25

04. Cold water rinsing

5—10 --- -- Untilcausticfree

05. Nitric acid solution

15-20 65—70 1.5—2.0

06. Cold water rinsing

5—10 -- -- Until acidfree

07. Hot water rinsing

5—10 75—80 --

Flow chart of CIP system


Cold water rinse 2-3 min

Treated with hot water at 65°C for 5-

10 minutes

1.5% alkali solution circulation for20-25

mintem. 80-85°C

Hot water 65°C circulation for 5

min

Rinse normal water for 5-10 min


Lactovita Dairy and Agro Ltd

Cleaned in Place (CIP) Log sheet.

No. ----------- Date:--------------------

Name ofPlant/Machin

e

Name ofChemical

%Chemica

l

Time Temp Flow RemarkFrom To

Note : Hot water, Caustic soda and Nitric acid are used in CIP.Manual on QC of Dairy product of 33

Circulation 1 % HNO3 solution for 15-20

min


_____________ ____________ ______________Shift In-charge Line In-charge Manager(Prod.)

Checklist for temperature and pressure:

Product Name Pasteurization Temp:

SterilizationTemp:

HomogenizationPressure

FillingTemp:

Vacuum/Gas

VolumeFluid milk pouch pack(Pasteurized)Fluid milk pouch pack(UHT milk)Mango milk packChocolate milk packGheeAny others

Sampling frequency for on line QC should be maintained as follows:

SL Name of item Quantitychecked

Frequency

01. Fluid milk pouch pack Pcs, pack / times / Manual on QC of Dairy product of 33


(Pasteurized) time shift02. Fluid milk pouch pack (UHT

milk)03. Mango milk pack

04. Chocolate milk pack

05. - Ghee

06. Any others

Standard limit for on line QC:

SL Name of item Brix Acidity(%)

pH others

01. Fluid milk pouch pack(Pasteurized)

02. Fluid milk pouch pack(UHT milk)

03. Mango milk pack04. Chocolate milk pack05. - Ghee06. Any others

Qc Parameters For On Line QC.

Check List of QC Parameter for products:

SL Liquid Dosage Product Standard limit01. Acidity02. Brix03. P H

04. Smell05. Organolaptic Test 06. Colour 07. Flavour 08. Ls09. Ts10. Filling Temp:11. Pasteurizing Temp:12. Sterilizing Temp:



13. Vacuum 14. Leakage 15. Coding 16. Volume 17. Label Setting 18. Clarity 19. Mfg & Exp.20. Hygiene & Sanitation

condition Observation in UHT Treatment:

After final standardization milk is ready for UHT treatment. DuringUHT treatment homogenization pressure, pasteurization temperature,etc are closely monitored by QC people.

Checklist for temperature and pressure:

Product Name Pasteurization Temp:

SterilizationTemp:

HomogenizationPressure

FillingTemp:

Vacuum/Gas

VolumeFluid milk pouch pack(Pasteurized)Fluid milk pouch pack(UHT milk)Mango milk packChocolate milk packGheeAny others

. Observation during filling of packs:

QC people collect samples of filled packs in every twenty minutesfrom conveyor during filling. Four packs are kept in incubation roomfor observation among the filling packs. From the observation packs,one pack is cut after 24 hours and tests its PH. Similarly remainingthree packs are cut after 72hrs, 120hrs and 3 months respectivelyfor testing PH, sedimentation and also acidity if necessary. Duringfilling, QC people, closely observes the following: (Can we introduceany checklist containing the below items? )



a) Checking of volume,b) Leakage, c) Date code, d) Sealing ande) Hygiene & cleanliness etc.

Hygiene and Sanitation:




Hygiene & Sanitation Monitoring Form.

Name of Production Line: -------------------------------------

Date: ---------------------

Description Initial ofworks

During work Final work Remark

Satisfactory

Unsatisfactory

Satisfactory

Unsatisfactory

Satisfactory

Unsatisfactory

ClothesApronCapHand glovesMask Gum bootHealthNail Hand cleaningLiaisonInfectious disease Health conditionFurniture & MachineFloor, wall & roof Lighting Insect killer Drain & cover Windrow & net Ventilator Screen of door Water line Pump &Motors Filling table Coding machine Conveyer& Truly Blending tank &Mixer



machineFilling & Cappingmachine Plastic dram & Tab Washing tankStream Jacket kettleRakes Suspend /Tray Wrapping machine Filling hopper

_______________ ____________________________Hygiene supervisor Hygiene InspectorDepartment Head

Part - C



01. Quality Assurance (QA):

2.1.1 Total Coliform Count (Format)

REF: 08.874 DATE: 19.11.05

Technique applied : Pour Plate Technique

Media used : EMB Agar.

Testing Date : 15.11.05

Result Counting Date : 17.11.05



SLNo:

Product Name ProductionDate & SampleCollection

Time

Acceptable Limit

ResultCFU/ ml

Remarks

01. Fluid milk pouchpack (Pasteurized)

02. Fluid milk pouchpack (UHT milk)


______________________ ________________ Test Performed by Approved by Designated QA Designated QC

2.2.1 Total Viable Bacterial Count (Format)

REF: 08.874 DATE: 19.11.05Manual on QC of Dairy product of 33



Media used : Standard Plate Count Agar



SLNo:


Time

Acceptable Limit

ResultCFU/ ml

Remarks







2.3.1 Total Yeast & Mold Count (Format)

REF: 08.874 DATE: 19.11.05


Media used : Potato Dextrose Agar



SLNo:


Time

Acceptable Limit

ResultCFU/ ml

Remarks







4.1 Report on post production for Quality Test:


QUALITY TEST REPORT ON POST PRODUCTION.

Testing date:Manufacturing Date:Expiry Date:Test Parameters StandardVolumeColourFlavourAcidity (%)pHFe (ppm)TDS(ppm)Total Hardness(ppm)Ls & TsConductivityOrganolaptic TestLabel & pack conditionCarton conditionChecking



Quantity(Random)Total QuantityClearance Date Remarks ______________________ ________________ Test Performed by Approved by Designated QA Designated QC

05. Shelf Life Study including Incubation procedure:

LACTOVITA DAIRY AND AGRO LTDQUALITY CONTROL

INCUBITION TIME AND TEMPARATURE FOR MICRO-BIOLOGICAL TEST

SL PRODUCT NAME INCUBATION TIME INCUBATION TEMPARATURE



NOTE 1: If the Temperature comes down below 300 C (300 C-250 C) then Incubation time will be increased (3 to 7 days) i.e. it depends on the nature of the products.

NOTE 2: Affix appropriate sticker onto every product and maintains aRegister of the same.

5.2 Product shelf life study record:


PRODUCT SHELF LIFE STUDY RECORD FORM

Name of product :



MFG date :

Collection date :

SINo.

Observationdate

Chemicaltest

Organoleptictest

Microbiological test.

Remarks Sing

____________ _____________ Checked by Approved by

06. Inspection of finished Goods in ware house:



Finished products are kept in warehouse / go down for distribution.On the next day QC people visit the warehouse and test the finishedproducts both physically & chemically before distribution. Theyensure that the stickers of “QC passed”, “under test”, “hold” etcare pasted on the product which is mandatory for eachproduct/carton.

07. QA Should assure FIFO method:

QA should also monitor FIFO method at Finished Goods Store. Everyproduct has a shelf life. Product should be delivered First comeFirst serve basis.

08. Clearance Certificate of finished goods as per approved format:

When the product is ready for distribution, QC department issues clearance certificate for the product intended for delivery / distribution on the basis of finished product inspection report and microbiological report.




PRODUCT SHELF LIFE STUDY RECORD FORM

Ref:No.

ToStore In-charge,

This is to certify that flavour____________________Mfg.date__________

Batch and Qty. ______________________________________________________________________________________ Total Qty of _______________

had been tested as per standard procedure and found to besatisfactory. The same can be dispatched.Parameter:

1.

2.

3.



4.

5.

Note:

___________________ _____________________ Assist. Manager (QA)Designated QC (Dairy) Clearance confirmed:Approved

From NO: 10-03-QA-F-04.


Quality Control Dairy Lactovita

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