Quality Control in Dairy and Meat

Industry.

Group No 05.

.

QualityMeans

Value for money

Zero defects

Guarantee of confidence

On time delivery

Customer satisfaction

Fitness for use

• Technological characteristics. Ex:Length , weight , Hardness

• Physiological characteristics. Ex: Color , Odor , Taste , Texture

• Time oriented characteristics. Ex:Reliability, Maintainability

• Ethical(especially for service) Ex:Courtesy ,Honesty

• Contractual. Ex:Guarantee provisions

Quality Characteristics

Quality Parameters• In building the required quality characteristics into

quality product so that product will be fit for use by the consumer due to quality parameters. Quality of design. Quality of conformance(quality of manufacture). quality of management. quality of technology. quality of man power.

Quality Control….

Quality control is a process employed to ensure certain level of quality in a product or service. It may include whatever actions a business deems necessary to provide for the control and verification of certain characteristics of a product or service.

Why Quality Control Need To ensure economic production of products of uniform quality acceptable to the customer

Aims at preventing the defects rather than detecting the defects.

Increased productivity

Reduced cost of repairs

Increases loyal customer base

Better profits

4 M’s in Quality control.• Affecting factors in quality control process.

4 M’s

Materials

Machines

Man power

Methods

InputTransform

Mechanism Output

Quality control sequence

Take action if any on the difference.

Interpret the difference between the actual and the standard.

Measure the actual performance.

Choose the sensing device which can measure the control subject in terms of the unit of measurement.

Set a standard or a goal for the control subject.

Choose unit of measures

Quality Control in Milk

What is milk quality control?

• Milk quality control is the use of various tests to ensure that milk and milk products are safe, healthy, and meet the standards for chemical composition, purity, and levels of bacteria and other micro-organisms.

Why do we need a milk quality control system?

A quality control system will test milk and milk products for quality, and ensure that milk collectors, processors and marketing agencies follow

the correct methods.

Milk is indispensable in day to day life and is a highly perishable commodity, which can be easily adulterated and its quality can be

easily altered by a large variety of factors.

Milk is consumed by human. Contaminants can harm to human health.

The demand for milk has significant increase during recent years follwing to a substantial improvement in the economic conditions . These developments

have lead to the improvement in the milk supply to the people particularly in the urban areas.

Milk producers:

• with a good quality control system, farmers can get a fair price in accordance with the quality of milk.

Milk processors

• the milk processor who pays the farmer can be sure that the milk is of good quality and is suitable for making various dairy products.

Consumers

• they will pay a fair price for quality milk.

Government

agencies:

• with a good system, the government can protect the health of consumers , prevent contaminated and sub-standard products, and ensure that everyone pays or receives a fair price.

a good quality control system will provide benefits to everyone involved in the dairy industry.

At farm Level

At collection center

At Storage and Transport

At production systems

Contamination and Control Measures at Farm Level

• Contamination of milk can occur at the following levels.

• Contaminants:-• Mud, urine and feed residues

• Control measures:- • proper drainage ,light and ventilation.• Clean & disinfect floor.• Should have separate milking parlors.• Non slippery floor lined with bricks or

cement.

1Animal shed

and environment

• Contaminants:-• Dung ,Hairs ,somatic cells ,microbes and

other factors.• Control measures:-

• Clean cow before milking with clean water.

• Groom the cow before milking.• Dry udder by clean cloths.• Animals suffering from any contagious

disease, including mastitis, should be segregated from the healthy ones.

• Milk from diseased animals should be kept separate and disposed of safely.

• Long hairs on the flanks, hind legs, tail and udder should be clipped at frequent intervals.

2.The Animal ,

its health and

management

• Contaminants:-• Injuries ,infection diseases ,Dirty

cloths ,nails ,hairs like body parts.

• Control measures:-• Use clean cloths to clean udders.• Clean hands ,cover hair before milking.• The milk should be drawn directly into the pail as

fast as possible.• After milking, the teats can be dipped or sprayed

with a gentle antiseptic solution.• Follow correct milking methods.

3.Milker

and milkin

g routin

e

• Contaminants:-• Dirty milking equipment ,dents, rust ,milk

residues ,dust• Control measures:-

• About 15 minutes before milking, milking equipment should be rinsed with a sanitizing solution.

• milking equipment thoroughly cleaned after use.

• The utensils and equipment used during milking should be of standard quality.

• The utensils and equipment should not have any joints or open seams and should be free from dents, rust

4.Milking

equipment

Quality Measures at Chilling Centre

Milk Collectin

g

Chilling Centre

Milk Quality• Taste• Smell• Odor

Reject

- Resazurin Test

- H2O2 Test- Sugar Test- Salt Test

Head Office

Store milk under 4◦C

Up to 2 days in a 1600L –

2200L capacity tank

Quality Measures at Collection centersfilter the

milk

Alcohol test

Resazurin Test

Quality incentives

Adulteration machine

FatSNF

WaterSalt Sugar

Urea

Sucrose

Storage• Before storage, it is best to filter the milk with a clean cloth in

order to remove large particles that might have entered the milk. The cloth should be thoroughly cleaned after use and left to dry in the sun.

• Heat, light and violent movement can all cause breakdown of certain components in the milk. Milk should therefore be cooled as quickly as possible.

• In case chilling is not feasible, preservatives like lactoperoxidase can be added to prolong the time before the milk gets spoiled.

• Milk should be stored in clean containers with a lid and kept in a cool and shady place where the danger of contamination is minimal.

Transport• Milk should be transported in clean containers.• Transport time should be kept to an absolute

minimum and violent movement of the milk should be avoided as milk fat can soon turn rancid in the presence of oxygen.

• When transporting record the milk collecting time at each collection center.

Quality Measures in Production Systems

• Evaluate milk quality after bowser entering to the factory.

• Before processing again test milk quality.• After mixing all ingredients test whether

mixture is achieve recommended standards.• During processing again test quality several

times.• Test quality of product at final stage.

Dairy products and qualityparameters

• Liquid milk• Milk powder• Butter• Yoghurt• Curd• Acidified milk• Condensed milk• Ice cream

Dairy products and quality parameters1.Liquid milk

Homogenized milk

Raw milk

Standardized milk

Low fat milk

Flavored milk

Skimmed liquid milk

Toned milk

2.Milk powder

Non fat (skimmed) milk powder

Full Cream milk powder

Low fat milk powder

Nutritional powders

3.Butter

Salted butter

unsalted butter

4.Cheese

Hard

Semi-hard

Soft ripened or ripened

Processed cheese or cheese spread

5. Yoghurt• Obtained from the coagulation of milk by • Streptococcus thermophilus and• Lactobacillus bulgaricus• All yoghurts should have 8.0% min SNF

(Solids Non Fat = 100 – moisture –fat )

• Standard yoghurt = 3% min milk fat• Low fat yoghurt = 0.5 – 3% milk fat• Non fat yoghurt = < 0.5% milk fat (not much commercially produced due to bland taste)• Fruit yoghurt = at least 5% fruit content

6.CurdObtained from coagulation of milk by Streptococcus lactis, S. diacetylactis,S.cremoris, S.thermophilus and Lactobacillus

bulgaricus These can be obtained from purified cultures or curd itself7.Acidified milk – liquid milk

acidified with lactic or citric acid at controlled levels, a more convenient substitute of fermented milk

8.Powdered acidified milk Also available eg. Powdered acidified milk with fruit flavors Preferred in countries such as Philippines, Taiwan.

9.Condensed milkconcentrated by removing water and sweetened by adding sugar

Total milk solids 31% min , Milk fat 9% min , Sucrose 40% min.10.Ice cream• Total solids 32% min• • Fat 8% min• • Sucrose 10% min• • SNF 8% min• • Mass 475 g per litre min

Quality control of meat

Quality of meat• Steps to Good Animal Husbandry…• 1. Identify your animals• 2. Maintain good records• 3. Take care of medicines and necessary supplies• 4. Work with your vet for prescriptions• 5. Share your knowledge with your family• 6. Use drug residue tests when you should• 7. Put together an effective herd health plan• 8. Provide proper animal care!!!• 9. Mix and store feeds properly• 10.Enjoy being a producer of high quality produc

Quality control in Chicken• Main aim of quality control plant in poultry

Providing products of uniform quality as per the standards(free from pathogen) and aesthetically acceptable.• In quality control check in different levels such as processing

dock, processing line and packing area.• At processing dock---- Average live weight on arrival and

feathering are noted.• At processing area ----- fleshing, color, incidence of breast

blisters, wing conditions are noted.• Packing area -------- pack out according to grades.• After processing proper disposal of processing waste

condemned are part also important for quality control programme.

Sausage is a prepared food

• Ingredients of sausages• Ground / minced meat , Water / ice ,Edible common salt ,

Curing salt; Sodium or Potassium Nitrite or Nitrate ,Potassium chloride ,Spices ,Seasoning and condiments ,Fillers / binders / emulsifiers / extenders (wheat rusk , potato starch, rice starch, bread, biscuits, maize floor, mil ,powder, caseinates, whey powder, egg protein, blood serum, gluten, soy floor)

• Sugar, dextrose ,antioxidants; tocopherol, Ascorbic,Acidity regulators; Lactic or Citric acids ,Smoke solutions

• Sodium or Potassium Phosphates ,SMS ,fats / oil; vegetable fat, animal fat

• Casing; Animal intestine, artigficial

Quality requirements for sausages Organoleptic

requirements

• Appearance• Texture• Flavors

Chemical requirements (SLS:1218)

• Lean meat 40% min• Total meat 60% min• Fat 20% max• Starch 4% max• Total solids 33% min• NaCl 2.5% max• SO2• 500 ppm max• Acid insoluble ash 0.5

% max• NaNO2• 125 ppm max• Arsenic 1.0 ppm max• Copper 20.0 ppm max• Lead 1.0 ppm max

Microbiological requirements

• Stphylococus aureus 1000, 100 / g

• E.coli 500, absent / g• E.coli O157 absent,

absent / g• Salmonella absent,

absent / g

• It causes lumping, color change in milk powder• Encourages microbial growth leading to further

spoilage ex. Spoiling of cheeseWater

• Causes coagulation, discoloring and bad dour in liquid milks

• Fungal and bacterial growth .

Harmful microorganisms

• Results in oxidation of fats and causes rancidity of milk powder, butter etcExposure to air

• May impart bad dour, taste or color ex. Milk drinks prepared from hard water tastes unpleasant

Impurities (minerals in water)

• Unpleasant appearance• May cause injury

Visible extraneous matter ex. haïr ,

nail etc.

• Gelatin layers over yoghurt , Large ice crystals in ice cream• Separation of cream and water in yoghurt or ice cream

(weeping)

Effects of poor processing

Factors Affecting Quality of DairyProducts

Analysis of abnormal milk

Organoleptic tests

Appearance

color

Odor ,smell , taste

Tenderness & Juiciness

Chemical tests

Acidity test

Clot and boiling test

Alcohol test

Rezasurine test

Fat & SNF testAdulterants

test

Gerber’s method

Lactometer reading

Iodine test

Seliwanoff’s test

Standers for Milk & Meat in Sri Lanka

• ISO 9000• ISO 22000 – International standard for food &

safety• HACCP• WHO food standards – Codex Alim entarias• Global red meat standard• Safe quality food programme

ISO

• The International Organization for Standardization (ISO) is an international standard-setting body composed of representatives from various national standards organizations. Founded on 23 February 1947, the organization promotes worldwide proprietary, industrial and commercial standards.

ISO 9000

• ISO 9000 is a quality management standard that presents guidelines intended to increase business efficiency and customer satisfaction.

• The goal of ISO 9000 is to embed a quality management system within an organization, increasing productivity, reducing unnecessary costs, and ensuring quality of processes and products.

The ISO 9000 family comprises the following standards;

• [ISO 9000:2000] - the basis of the quality management systems and terminology.

• [ISO 9001: 2000] - specifies requirements concerning the quality management system.

• [ISO 9004:2000] - specifies guidelines for the improvement of the system already implemented.

Advantages of ISO 9000

• Creates a more efficient, effective operation• Increases customer satisfaction and retention• Reduces audits• Enhances marketing• Improves employee motivation, awareness, and

morale• Promotes international trade• Increases profit• Reduces waste and increases productivity

ISO 14001

• This is an internationally agreed standard that sets out the requirements for an environmental management system.

• The Environment Management System (EMS) Standard ISO 14001 provides a useful guide.

Advantages of iso 14001

• Identify cost savings with greater emphasis on resource, waste and energy management.

• Develop the corporate image and credibility.• Quantify, monitor and control the impact of operations on the

environment, now and in the future.• Ensure legislative awareness and compliance.• Improve environmental performance of supply chain.• Protect the company, assets, shareholders and directors.• Potentially decrease public liability insurance costs for your

organization.

ISO 22000

• Food Safety Management System that can be applied to any organization in the food chain, farm to fork.

• ISO 22000:2005 integrates both the quality management system (ISO 9001:2000) and HACCP system.

Benefits of ISO 22000• Internationally-recognized, harmonized standard for

controlling food safety hazards• Flexibility, allowing it to be applied to all organizations in the

food supply chain.• Possible integration of the food safety and quality

management schemes within an organization (e.g. ISO 9001)• Provides a framework for management commitment,

communication with suppliers and customers, and continuous improvement of the food safety system

• Demonstrates an organization’s commitment to food safety

HACCP SYSTEM

• Hazard Analysis and Critical Control Point (HACCP) • systematic preventive approach to food safety from biological,

chemical, and physical hazards in production processes that can cause the finished product to be unsafe, and designs measurements to reduce these risks to a safe level.

• The HACCP system was first made public during the 1971 National Conference on Food Protection.

• HACCP principles are included in the international standard ISO 22000 FSMS 2005.

• This standard is a complete food safety and quality management system.

Principles of haccp system

1. Conduct a hazard analysis & assessment.2. Identify critical control points.3. Establish critical limits for each critical control point.4. Establish critical control point monitoring requirements.5. Establish corrective actions.6. Establish procedures for ensuring the HACCP system is

working as intended.7. Establish record keeping procedures.

HOW TO CONDUCT A HAZARD ANALYSIS

• The first step is to identify the threats to human health which might be introduced into meat and poultry products during processing.

• These hazards are usually grouped into three categories:– Biological Hazards– Chemical Hazards– Physical Hazards

Biological Hazards

• Biological hazards are living organisms that can make food unsafe to eat (bacteria, parasites, or viruses)

• Biological hazards are frequently associated with the raw materials.

• Biological hazards may be also introduced during processing by;– People involved in the processing– from the environment in which foods are processed– from other ingredients in the products– from the processes themselves

• Some of the major pathogens that may be associated with meat and poultry products are: – Salmonella,– Escherichia coli– Clostridium botulinum– Staphylococcus aureus

Chemical Hazards

• Chemical hazards may be something which occurs naturally in foods, or something added during processing.

• Naturally occurring chemical hazards are those that are natural constituents of foods and not the result of other environmental contamination.

• They include aflatoxins, mycotoxins and shellfish toxins.• Added chemical hazards are those which are added to

food during growth, harvesting, storage, processing, packaging or distribution.

Physical hazards

• It is a component of a food that is unexpected and may cause illness or injury to the person who consuming the food.

• Foreign materials such as glass, metal or plastic etc.

• More than one preventive measure may be needed to control a food safety hazard, while more than one hazard may be controlled by a preventive measure.

• However this is often a difficult and time consuming step.

Application of haccp system

• Fish and fishery products• Fresh-cut produce• Juice and nectar products• Food outlets• Meat and poultry products• School food and services

safe quality food program

• SQF is designed as a food safety program, but it also covers product quality.

• It is designed to meet the needs of retailers and foodservice providers who require HACCP and ISO based food safety and quality management systems from their suppliers.

• There are three levels of certification– Level 1: Food Safety Fundamentals– Level 2: Certified HACCP Food Safety Plans– Level 3: Comprehensive Food Safety and Quality

Management Systems

References

• Khamer Sheeba (2004),Milk Production and processing

• Lecture notes of Diploma in Food Quality Management.