Creamery Juice HACCP Plan New - Rtfword

Penn State Berkey Creamery Juice HACCP 2014
Berkey Creamery
Juice HACCP Plan

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Penn State Berkey Creamery Juice
HACCP 2014
Table of Contents:
HACCP Team and Product Statement with Process Flow Diagram……………………… pg.3
HACCP Verification Sheet…………………………………………………………………………………… pg.4
Hazard Analysis Summary Table………………………………………………………………………… pg.5
HACCP Plan Summary Table………………………………………………………………………………. pg.6
SOP 002.002 Orange Juice Production…………………………………………………………………….. pg.7
8 SSOPs………………………………………………………………………………………………………………….. pg.9
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HACCP Team for the Penn State Berkey Creamery:
Mr. Martin Bucknarage Mr. Thomas Palchak Mr. James Brown
Ms. Bonnie Ford Mr. William Kurtz Ms. Susan Watson
Mr. Terry Grove
BERKEY CREAMERY PRODUCTION AND DISTRIBUTION FLOW DIAGRAM
Product: 100% Pure Florida Orange Juice from Concentrate

Ingredients: Water, orange juice concentrate
Processing: All ingredients are pasteurized (161°for15sec.)
Labeling and Use Instruction: Coded with sell by date, and keep refrigerated
Confirmatory Test: No protein present in product
Packaging: 1gal, 1/2gal, qt, and pint HDPE plastic bottles with
tamper evident seals.
Transportation and Distribution: Stored and distributed under 45°F
Intended Consumers: University dining halls and Creamery store
Shelf Life 45 days from code dating
Orange
Juice
Concentrate
Received and
University Water
stored under
Supply
(-20°F)
Mixing
Drums thawed and
(balance tank of Water Softener
stored under 45°F
HTST)
Pasteurization
1 gal bottles
(CCP#1)
Pasteurized
½ gal Verification of Brix
Storage at or (11.8-12.2%)
bottles
below 45°F
Quart
In line metal
Packaging detector
(CCP#2)
bottles
Confirmatory
Pint bottles Test for
Protein
Storage and
Distribution
(under 45°F)
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BERKEY CREAMERY HACCP SYSTEM VERIFICATION SHEET
Evaluation of Product and Process YES No If Yes, describe Food Safety Are modifications of
Implications the HACCP plan of
Hazard Analysis
required?
Product description change?
Formulation change?
Ingredient change?
Packaging change?
New consumption or storage methods?
New suppliers?
Process Change?
Added or changed equipment?
Finished product description change?
Evaluation of Product Safety History
Excessive CCP deviations? Any
product recall?
Any new or emerging hazards? Any
food safety consumer complaints?
Evaluation of CCPs, Critical limits, Monitoring, Corrective actions, CCP Verification, Record keeping
Do the CCPs control the hazard? Are
the CCP critical limits adequate? Do
monitoring methods and their
frequency adequately identify
deviations?
Are record keeping procedures
adequate?
Do verification activities include the
calibration of process monitoring
instruments?
Does verification include review of
consumer complaints?
Does verification include the review of
records?
Are the prerequisite programs and/ or
SSOPs identified in the hazard analysis
as reducing the likelihood of hazards still
effective?
Verification conducted by: __________________________________________

Signature of Laboratory Director:_____________________________________
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Berkey Creamery Hazard Analysis Summary Table

· Process, Step, Ingredient or Input · Identify the Potential Hazard · Is the hazard severe and · Is a control measure available at this hazard ·D
· (B)iological of sufficient likelihood to correctly applied, monitored, and documented t
· (C)hemical warrant its control? in a Prerequisite Program (PP) or other e
· (P)hysical procedure? o
· If not, could and existing PP be modified or a l
new PP established to control the hazard. · If
· If so, identify the PP and its location · If
· If “yes”, stop and document h
· If no, proceed to next question
Orange Juice Concentrate Receiving B Yes No
C Yes Yes: Certificate of Analysis; Product seals
P Yes Yes: Certificate of Analysis; Product Seals
Concentrate Storage B No
C No
P No
Ingredients: Water B Yes No
C Yes Yes: Must be potable; commercial lab certification
P Yes No
Pasteurization B Yes No
C No
P No
Packaging B Yes Yes: Letter of Guarantee

C No Yes: Letter of Guarantee
P No Yes: Letter of Guarantee
Product Storage B Yes Yes: SSOPs and GMP training
C No
P No
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Berkey Creamery Hazard Analysis Summary Table
Critical Control Hazards Critical Limits Monitoring Corrective Actions

Point
What How Frequency Who
CCP#1 Biological‐ Temperature as Temperature Safety Continuous Pasteurizer Automatic diversion C
Pasteurization Vegetative measured at the thermal limit operators of product flow p
(HTST without a Pathogens (non‐ exit of the holding recorder and
magnetic flow spore formers) tube must exceed chart recorder Isolation of affected In
meter system) 161°F product re
th
Holding Time must Time Timing pump Evaluate and co
be greater than 15 determine the
seconds disposition of the P
product d
Pressure Pressure Pressure ch
differential differential Document all actions
between controller Eq
pasteurized and ca
raw product must
be greater than Se
1p.s.i
Critical Control Hazards Critical Limits Monitoring Corrective Action Ve

Point
What How Frequency Who
CCP #2 Ferrous material No ferrous Ferrous material Metal Detector Continuous Bottle Filling Quantity of juice M
At entry point of material in Operator is discarded mai
filling machine product
Isolate affected
product
Document
actions
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SOP: 002.002 Effective Date: 11/29/06
Supersedes SOP: 002.001 Effective Date: 08/25/04
STANDARD OPERATING PROCEDURE – Orange Juice Production

INTRODUCTION
Orange juice is prepared from a concentrate, pasteurized, and then packaged for wholesale and retail
distribution.
MATERIALS
1. Supplies
a. Sanitizer
b. Swabs that detect milk protein
c. Orange juice concentrate
d. Brix refractometer
e. Chart paper
f. Record of manufacture form
2. Hazards
a. Burns from hot water and hot metal.
b. Corrosive damage to eyes and skin from sanitizer. Wear goggles and gloves when
using the concentrate. Avoid breathing the vapors.
PROCEDURE
1. Pre‐production sanitation
a. Discard the sanitizing solution that was held in the filler bowls, allowing it to flow
through the filler tubes and onto the floor.
b. Prepare at least 300 gallons of sanitizing solution in a mixing tank. Test the
concentration and record the result on the sanitation test record.
c. Pump the sanitizing solution through the lines leading to the HTST, through the HTST,
and then to the tank that will be used for orange juice production. Finally, pump the sanitizing
solution from the orange juice production tank through the lines to the fillers, allowing it to
overflow the bowls and to flow through all of the filler tubes and then onto the floor.
d. Start the HTST and pasteurize some water. Run this water through the lines leading to
the tank that will be used for orange juice production, then through the lines to the fillers. Allow
the pasteurized water to overflow the bowls and to flow through all of the filler tubes and then
onto the floor.
e. Swab food contact surfaces. If results indicate the presence of milk protein residues
repeat the sanitation procedure.
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2. Production
1. Allow the frozen orange juice concentrate to thaw at < 45°F.
2. Prepare charts and start them recording the pasteurizing conditions and the
temperature of the pasteurized storage tank.
3. Pump some soft water into the mixing tank.
4. Add the orange juice concentrate and mix with high agitation.
5. Pump the orange juice through the HTST at a minimum of 161ºF and a holding time of at
least 15 seconds. The pasteurized juice should be directed into the pre‐sanitized pasteurized
storage tank.
6. Pasteurize the remaining volume of soft water and add this to the pasteurized storage tank.
7. With cooling and high agitation turned on, mix for at least 30 minutes.
8. Taste the juice and check the Brix. The Brix reading should be between 11.8 and 12.2
9. Swab food contact surface at filler nozzle for presence of milk protein.
10. Fill containers and store them at < 45°F.
RECORDKEEPING
1. Each day that orange juice is prepared a record of manufacture form should be filled out. This will
specify the ingredients used, the volume of juice made, and the results of the milk protein residue test.
2. Charts should be used to record the pasteurization conditions as well the temperature of the
pasteurized storage tank.
3. Record the results from the sanitizer concentration assays on the weekly sanitation test form.
4. Retain all records for at least two years.
REFERENCES
1. Penn State Berkey Creamery Juice HACCP Plan (most recent version).
2. SOP 005 Chart Usage
The following individual is responsible for implementation of this SOP and has the overall authority on‐site:
Name: ____________________________ Title: __________________________ Date: _______________
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SSOP: 001.002 Effective Date: 11/22/06
Supersedes SSOP: 001.001 Effective Date: 10/22/04
SANITATION STANDARD OPERATING PROCEDURE – Water, Steam, and Ice Safety

INTRODUCTION
Water is critical for food production and plant sanitation. Potable water, cooling water, steam and ice
must be safe and it must be available in sufficient quantities, at suitable pressures and temperatures, to meet
operational requirements.
The Berkey Creamery uses treated water from well fields owned and maintained by The Pennsylvania
State University. These wells provide water for the University Park Campus of Penn State and are the state
approved source of all water needs, including the cleaning and rinsing of equipment.
FACILITIES
1. Potable water supply:

a. The potable water supply, including the soft water system, is maintained by the
Pennsylvania State Universities Office of Physical Plant. All water entering the building,
including the water that is used as an ingredient or that goes to the refrigeration system,
passes through a chlorination process.
b. Bacteriological testing of the potable water is conducted monthly by Penn
State and semiannually by an approved commercial laboratory.
c. Water pipes, hoses, and other connections that could possibly result in contamination
of the potable water supply must be equipped with properly designed physical breaks, anti‐
siphon or anti‐backflow devices.
d. Cross connections between potable and non‐potable water supply systems must not exist.
2. Cooling water supply:
a. The cooling water supply is maintained and tested monthly by a commercial water
treatment company.
b. Water treatment chemicals may be added according to the manufacturer’s
directions when needed.
c. Bacteriological testing of the cooling water is conducted semiannually by an
approved commercial laboratory.
3. Steam supply:
a. The steam supply is maintained by the Pennsylvania State University Office of Physical
Plant.
b. Unfiltered steam does not come into direct contact with food or food contact surfaces.
c. Filtered steam originates from potable water.
d. Culinary steam is carbon filtered. The filter is to be changed every six months, and
verification records kept.
4. Ice supply:
a. Ice making machines are maintained by the Pennsylvania State University Office of Physical
Plant.
b. All ice is made from potable water.
c. Ice is handled and stored in a manner that protects it from contamination.
5. Reclaimed water supply:
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a. The Creamery does not use reclaimed water.
6. Distilled water supply:

a. The distilled water supply is maintained by the Pennsylvania State University Office of
Physical Plant.
RECORDKEEPING
1. The University maintains documentation on the water tests conducted for chemical,
microbiological, turbidity and radiological parameters.
2. Microbiological test results of the water supply that are conducted by Penn State are
maintained in the Office of Physical Plant.
3. All other results from the analysis of the potable and cooling water supplies are maintained at the
Berkey Creamery for at least two years.
The following individual is responsible for implementation of this SSOP and has the overall authority on‐site:
Name: ____________________________ Title: __________________________ Date: _______________

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SANITATION STANDARD OPERATING PROCEDURE – Processing Equipment Cleaning and

Sanitation
INTRODUCTION
Clean and sanitized processing equipment and utensils are essential to the manufacture of safe food
products. Processing equipment is cleaned after each day’s run and sanitized immediately prior to the next
use. Most equipment in a dairy plant is cleaned‐in‐place (CIP) using a computer controlled multi‐step system.
Items that cannot be cleaned with the CIP system must be cleaned and sanitized after each use by hand or in a
COP (cleaned out‐of‐place) tub.
MATERIALS
1. Supplies
a. Cleaning and sanitizing agents
b. Cleaning equipment such as gloves, brushes, buckets, and foam sprayers
c. COP tub
d. Sanitation test records
2. Hazards
a. Burns from hot water and hot metal parts
b. Chemical burns to the skin and eyes from exposure to cleaners and sanitizers. Wear
gloves and goggles when using the concentrated chemicals. Avoid breathing the vapors.
HAND CLEANING PROCEDURE
1. Utensils and items that cannot be adequately cleaned with the CIP system must be hand washed.
2. These items are dismantled and pre‐rinsed with water to remove the heavy soil, then hand
scrubbed using a chlorinated alkaline detergent, and rinsed again with water. Wire screens must be
autoclaved following hand washing.
3. The cleaned items are reassembled and sanitized prior to use using the CIP sanitizing circuit if
possible or dipped in a sanitizing solution.
CLEANED OUT‐OF‐PLACE PROCEDURE
1. Dismantle equipment to be cleaned and rinse with water.

2. Place the parts in a COP tub and fill the tub with approximately 150 to 200 gallons of water.
3. Turn the circulation pump on and heat the water to 170°F.
4. Slowly add the necessary amount of chlorinated alkaline cleaner.
5. Collect a sample of the cleaning solution and test the alkalinity and chlorine concentrations.
6. Circulate hot water and cleaner for at least 30 minutes.
7. Allow the COP tub to empty into a floor drain.
8. Rinse the equipment with an approved sanitizer.
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9. Visually inspect each piece of equipment for possible damage and the presence of residual cleaner.
10. Reassemble the equipment and return it to its storage area.
OPERATION OF THE RAW CIP CIRCUIT

1. The raw CIP circuit is used to clean the milk delivery truck, the raw milk silo, the raw milk
receiving lines and pump as well as the raw lines leading to the processing plant. Additionally, the two
mixing tanks and the Breddo Liqwifier are cleaned and sanitized using the raw CIP circuit.
2. If needed, the equipment is pre‐rinsed with water to remove most of the residual product.
3. The necessary line connections are made and the raw CIP program is activated.
a. The first step is a water rinse
b. Then water is heated and a chlorinated alkaline detergent is added. This solution is
circulated throughout the circuit while valves and agitators are periodically pulsed to aid in
soil removal.
c. The wash cycle is followed by a water rinse which cools down the circuit.
d. Finally an acid sanitizer is added, circulated throughout the circuit, and allowed to
drain to the floor.
e. The line connections are returned to their original configuration.
4. Prior to the equipments next use a CIP sanitation step is performed using an acid sanitizer.
OPERATION OF THE PASTEURIZED CIP CRICUIT
1. The pasteurized CIP circuit is used to clean the all of the pasteurized storage tanks, filler lines,
and the bottle and bag filling equipment.
2. If needed, the equipment is pre‐rinsed with water to remove most of the residual product.
3. The necessary line connections are made and the pasteurized CIP program is activated.
a. The first step is a water rinse
b. Then water is heated and a chlorinated alkaline detergent is added. This solution is
circulated throughout the circuit while valves and agitators are periodically pulsed to aid in
soil removal.
c. The wash cycle is followed by a water rinse which cools down the circuit.
d. Finally an acid sanitizer is added, circulated throughout the circuit, and allowed to
drain to the floor.
e. The line connections are returned to their original configuration.
4. Prior to the equipments next use a CIP sanitation step is performed using an acid sanitizer.
OPERATION OF THE HTST CIP CIRCUIT
1. The HTST CIP circuit is used to clean the bowl, homogenizer, separator, and pasteurizer, all of the
lines connecting these pieces to equipment, as well as the lines and valves leading to the pasteurized
storage tanks.
2. If needed, the equipment is pre‐rinsed with water and the bowl is allowed to overflow with water
in order to remove most of the residual product.
3. The necessary line connections are made and the HTST CIP program is activated following the
required initial ten minute delay.
a. The first step is a caustic rinse using an alkaline cleaner. This solution is circulated
throughout the circuit while valves are periodically pulsed to aid in soil removal. It is also
allowed to overflow the bowl.
b. The caustic rinse cycle is followed by a water rinse.
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c. The water is then heated and an acid detergent is added. This solution is circulated
throughout the circuit while valves are periodically pulsed to aid in soil removal. During this
time the bowl may be hand washed if needed.
d. An alkaline cleaner is then added to the acid detergent that is being circulated (caustic
override). During this time the heat is maintained and the valves continue to pulse periodically.
e. The wash cycle is followed by a water rinse which overflows the bowl and cools down the
circuit.
f. Finally an acid sanitizer is added and circulated throughout the circuit. This sanitizer
remains in the system until the equipment is used again.
g. The line connections are returned to their original configuration.
4. Prior to the equipments next use a CIP sanitation step using an acid sanitizer is performed.
a. The residual acid sanitizer (from step 3f above) is rinsed out with water.
b. A fresh solution of acid sanitizer is prepared in one of the mixing tanks.
c. The HTST is started up using its product setting (not CIP) and high speed. This will pump
the acid sanitizer from the mixing tank through all of the equipment that is scheduled to be used
that day.
CLEANING OF BURNED ON RESIDUE
1. Rinse out residual product.

2. Fill the tank with water and add a powdered chlorinated detergent.
3. Heat the solution to approximately 180°F and allow it to soak until the residue is softened and
able to be removed.
4. Make the necessary CIP line connections and initiate the appropriate CIP program.
CLEANING AND SANITATION OF ICE CREAM PROCESSING EQUIPMENT
1. The ice cream mix tanks are cleaned using the pasteurized CIP circuit described above.
2. The flavor vats and ice cream freezers are rinsed with water following each use. Then a solution
of hot water and chlorinated alkaline detergent is circulated through this equipment and the lines
connecting them. Following the cleaning step the equipment is rinsed with water.
3. Prior to each days operations the pasteurized lines, flavor vats, freezers, ingredient feeder, half‐
gallon and three‐gallon filling equipment, as well as all the lines connecting this equipment are sanitized
with a chlorine sanitizer. Residual sanitizer is flushed out of the lines by pumping approximately three
gallons of ice cream mix through the circuit and draining it onto the floor. On days when the Dixie cup or
pint filling equipment is used it is likewise sanitized prior to use with a chlorine sanitizer which is allowed
to drain to the floor.
4. After each use, the filling equipment is rinsed with water to remove most of the residual product.
Then it is hand washed with a chlorinated alkaline detergent and rinsed with water again. Additionally, at
the end of each week the filling equipment that has been used is washed using a self foaming chlorinated
alkaline detergent and rinsed with water.
CLEANING AND SANITATION OF BEVERAGE CONTAINER FILLING EQUIPMENT
1. The filling lines and equipment are cleaned and sanitized using the pasteurized CIP circuit
described above.
2. On days when dairy products are packaged the following additional cleaning and sanitizing
steps are preformed.
a. Prior to packaging the acid sanitizer which was retained in the filler bowls is drained
through the filler tubes and onto the floor. The nozzle heads are also sprayed with an acid
sanitizer.
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b. At changeovers (when one products is finished being packaged and another begins), the
product remaining in the bowl is expelled through the filler tubes. The area is then rinsed with
water and sprayed with an acid sanitizer.
c. When packaging is finished, the product that remains in the bowl is expelled through the
filler tubes and the area is rinsed with water. The bowl is flushed with water and the CIP
connection to the filler heads is made. All exterior surfaces are first hand washed with a
chlorinated alkaline detergent, then washed with a self foaming chlorinated alkaline detergent
and rinsed with water.
3. On days when non‐dairy products are packaged the following additional cleaning and sanitizing
steps are preformed.
a. Prior to packaging, the acid sanitizer which was retained in the filler bowls is drained
through the filler tubes and onto the floor. A new solution of acid sanitizer is prepared in a mixing
tank and pumped through all of the equipment and tanks that will be used that day. It is also
allowed to overflow the bowl and flow through all of the filler tubes. Pasteurized water is then
pumped through all of the equipment, bowl and filler tubes. The nozzle heads are sprayed with
an acid sanitizer.
b. At changeovers, the product remaining in the bowl is expelled through the filler tubes.
The area is then rinsed with water and sprayed with an acid sanitizer.
c. When packaging is finished the product that remains in the bowl is expelled through
the filler tubes and the area is rinsed with water. The bowl is flushed with water and the CIP
connection to the filler heads is made. All exterior surfaces are hand washed with a chlorinated
CLEANING AND SANITATION OF CHEESE PROCESSING EQUIPMENT
1. Cheddar and ricotta vats

a. The vats are sanitized prior to use with an acid sanitizer.
b. After use the residual product is rinsed out with water.
c. The vats are then filled with water and hand washed using both a powdered
chlorinated detergent and a chlorinated alkaline detergent.
d. Following cleaning, the vats are thoroughly rinsed with water.
2. Kettle and homogenizer
a. Prior to use the kettle is filled with water which is heated to 180 °C. This water is
circulated within the kettle, pumped through the lines to the homogenizer, and then
drained onto the floor.
b. Following use, the residual product is rinsed out of the kettle with water.
c. The kettle is then filled with water and a powdered chlorinated detergent and heated.
This detergent solution is circulated within the kettle, pumped through the lines to the
homogenizer, and then drained onto the floor.
d. Additionally, the homogenizer is dismantled, washed by hand with a chlorinated
3. Cone‐bottom processor and pasteurized storage tank (PT6)
a. The cone‐bottom processor and PT6 are sanitized prior to use with an acid sanitizer.
b. Following use, the residual product is rinsed out with water.
c. The door gasket, fill lines, and exterior surfaces are hand washed with a chlorinated
d. Then the necessary line connections are made and the CIP program is activated.
4. Yogurt filler (PT7)
a. Prior to use a solution of chlorinated alkaline cleaner is prepared and flushed from
the filler bowls, over the track and then drained onto the floor.
b. Following use, the residual product is rinsed off with water.
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c. The removable parts of the filler are cleaned in a COP tub with a powdered chlorinated
detergent and rinsed with water.
d. All exterior surfaces are hand washed with a chlorinated alkaline detergent and
rinsed with water.
5. Cheddar processing equipment
a. Following use the cheddar press is rinsed with water, hand washed with a chlorinated
alkaline detergent, and then rinsed again.
b. The cheddar mill is sanitized prior to use. After each use it is rinsed with water, hand
washed with a chlorinated alkaline detergent, and then rinsed again.
c. The vacuum packager is sanitized using a chlorine soaked cloth prior to use and cleaned
with an aerosol cleaner following use.
d. The cheddar pans and liners are dipped in a solution of chlorine sanitizer prior to use.
After use the liners are discarded and the pans are rinsed with water. The pans are then cleaned
in a COP tub with a powdered chlorinated detergent and rinsed with water.
VALIDATION
1. Cleaned equipment and utensils are visually inspected to determine if they are free of residue and
foreign material.
2. Periodic swabbing of cleaned equipment with ATP bioluminescence swabs is used to monitor food
contact surfaces for the presence of residual soil.
3. Swabbing with milk protein detecting swabs prior to the manufacture of non‐dairy drinks is
used to monitor for possible cross‐contamination.
4. Samples are automatically collected from the various cycles within each CIP program. These are
titrated to determine their chemical concentration. If the concentrations are not consistently within an
acceptable range the chemical injection time will be adjusted.
RECORDKEEPING
1. Results from the chemical titrations of cleaning and sanitizing solutions are recorded on the
sanitation test records. These tests are performed to determine the concentrations of cleaning and
sanitizing solutions used in both the CIP system and the COP tubs.
2. Results obtained from ATP bioluminescence swabs are recorded on ATP monitoring forms.
3. Results obtained from milk detection swabs are recorded on the records of manufacture for
non‐dairy drinks.
Name: ____________________________ Title: __________________________ Date: _______________
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Superseded SSOP: 003.002 Effective Date: 11/27/06
SANITATION STANDARD OPERATING PROCEDURE – Cross‐Contamination Prevention
INTRODUCTION
During processing there are numerous ways that a product can become contaminated with a microbiological
hazard. The three most common means of cross‐contamination are contact with unclean equipment, mixing
pasteurized with raw products, and environmental contamination.
PROCEDURE
1. Periodically monitor equipment such as silo tanks, valves, agitator shafts, shielding and venting
for cracks and crevices. Improper welds and irregular surfaces are difficult to clean and sanitize properly
and thus can become a harborage for microorganisms.
2. Product handling:
a. Minimize the amount of a food products handling, environmental exposure,
and time / temperature abuse following pasteurization.
b. Discard any product that has been mishandled, not protected from
contamination, or not maintained at 45ºF (7.2ºC) or less.
c. When reclaiming products, re‐pasteurization is required, using higher temperatures
and /or longer holding times. All equipment involved in the reclaiming process should be
cleaned and sanitized daily.
d. Isolate returned products and outdated products from all other plant operations.
3. Cleaning supplies:
a. Eliminate the use of absorbent items such as rags and sponges in processing areas, as
well as porous materials such as wooden handled tools and brushes. Use impervious materials
such as metal or plastic instead.
b. Brushes should be segregated; raw and pasteurized, internal and external surfaces.
c. Brushes should be maintained in good condition, sanitized between uses, and stored
properly when not in use.
4. Utilize shielding over food and food contact surfaces to minimize contamination with
condensate, aerosols, dust, and other airborne hazards.
5. Monitor the cleanliness of overhead shielding, conveyors, conveyor belts, chain rollers and
supports. Maintain a cleaning and sanitizing regimen for all conveyors.
6. Air blow and agitation equipment should be monitored for cleanliness. These are not usually
cleaned adequately by CIP methods and therefore should be dismantled, cleaned manually, and
sanitized daily.
7. Do not break or slash containers over top a vat.
8. Exercise care when handling packing materials, especially where open containers are conveyed
through non‐processing areas.
9. Heating, ventilating, and air conditioning systems:
a. Should maintain positive pressure in areas where food products are exposed.
b. Minimize air flow from potentially contaminated areas to processing and packaging areas.
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c. Outside air should be filtered and free of condensate.
d. Air flow should be controlled so that it does not blow directly onto food, food contact
surfaces, as well as filling and packaging areas.
e. Air filters must be effective in preventing the passage of microorganisms. They must also
be kept clean and replaced when needed.
f. All heating, ventilating and air conditioning systems should be periodically cleaned,
including air systems in refrigerated areas.
g. Condensate drip pans and drain lines should be regularly monitored to ensure they
are not providing an environment for microbial growth.
10. Process air systems:
a. Systems that incorporate air directly into the food product must be easily cleaned and
designed to minimize contamination.
b. Process air systems should contain filters that are capable of removing extraneous matter.
c. Sanitary check valves that prevent product from backing up into the air lines should be
provided when necessary.
11. Use of push carts in the Food Science Building:
a. There is a risk of cross‐contamination when push carts are removed from the Creamery
and used to transport items to the third and fourth floors in the Food Science Building and vice
versa. Therefore push carts used in the Creamery processing plant, Food Science pilot plants and
sensory laboratory will have blue tape on their handles, and push carts for the third and fourth
floors will have red tape on their handles.
b. Blue labeled carts are used to transport food and food ingredients on the first and second
floors. In order to improve barrier hygiene methods they should not be taken to the fourth floor.
c. Red labeled push carts should not come in direct contact with any food or ingredients.
Items sent or shipped to the third and fourth floors should be transported on red labeled carts
or a dolly. If these carts are used to take supplies from the loading dock to the third and fourth
floors, they should not leave the immediate vicinity of the freight elevator. When not in use red
labeled carts should be stored on the third fourth floors.
d. Containers, samples, ingredients, packages and laboratory equipment should not be
transferred from one type of cart to another.
e. If you have any safety concerns or think that accidental cross contamination has
occurred, call the Creamery office at 814‐865‐7535 immediately.
Name: ____________________________ Title: __________________________ Date: _______________
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SANITATION STANDARD OPERATING PROCEDURE – Maintenance of Sanitary Facilities
INTRODUCTION
The production of safe food begins with proper sanitation. In addition to clean food processing
equipment, the facilities that are associated with food production areas must be clean and properly
maintained.
MATERIALS
1. Cleaning equipment and supplies

2. Chemical cleaning agents are stored in locked rooms away from food handling areas.
FACILITIES
1. Washrooms, lunchrooms, and changing rooms:

a. Washrooms are maintained by the Pennsylvania State Universities Office of Physical Plant.
b. Washrooms, lunchrooms and changing rooms should be separate from and not lead
directly into food processing areas.
2. Hand washing and sanitizing facilities:
a. Washrooms should have an adequate number of properly maintained hand‐washing
facilities that are directly connected to sanitary drains.
b. Hand washing facilities should have hot and cold potable running water, soap,
sanitary hand drying supplies or devices, and clean waste receptacles.
c. Processing areas should also have an adequate number of conveniently located and
properly installed hand washing facilities.
d. It is recommended that hand washing notices be posted in strategic points throughout
the processing plant to remind employees and visitors to wash hands after using the bathroom.
Name: ____________________________ Title: __________________________ Date: _______________
Page 18 of 25

SANITATION STANDARD OPERATING PROCEDURE – Adulteration Prevention
INTRODUCTION
Food, food packaging materials and food contact surfaces must be protected from adulteration with
physical or chemical hazards. Contaminants may include water, cleaners, sanitizers, lubricants, pesticides,
metal, rubber and plastic. The inclusion of unintended ingredients and undeclared allergens is also considered
to be product adulteration.
GENERAL ADULTERATION PREVENTION PROCEDURES:
a. Review all piping to ensure that products are not being contaminated.
a. Look for lines where products, or cleaning and sanitizing solutions could become trapped.
b. Examine drain lines to make sure they are draining freely except during use.
c. Monitor for cross‐connections between raw and pasteurized lines, between product lines
and
cleaned‐in‐place (CIP) circuits.
2. Inspect the sweet water system and any equipment that utilizes sweet water for leaks and
cracks. Monitor the water for harmful contaminants.
3. When alterations are made in the process piping or equipment, change the blueprints to
reflect those alterations.
4. As part of a routine preventative maintenance program examine air valves, screens, gaskets,
seals, o‐ rings, and other metal, rubber and plastic parts on processing equipment for wear.
5. Change the filters on the air blow system frequently.
6. Use extreme caution when reworking products.
a. Ensure that all reclaimed products have been pasteurized before reuse.
b. Make certain that reclaimed product is not used in the same lines or processing
equipment as pasteurized product unless they have been cleaned and sanitized between
uses.
c. Do not reclaim products from damaged or dirty containers.
d. Do not reclaim products that are beyond the normal shelf life.
e. Do not reclaim products that have been held at elevated temperatures.
f. Do not reclaim products that have been exposed to chemical or biological contamination.
ALLERGEN CONTROL PROCEDURES:

1. Utilize product and ingredient labels.
a. Ingredient labels identifying all allergenic foods must be on all containers offered for
sale. The precautionary “contains” statement must be clearly visible after the ingredient
statement.
b. Record all ingredients and their lot number on the records of manufacture as well as
the lot numbers of all food contact packaging materials.
c. Date coding must be shown on all products.
d. Ensure that packaging labels and ingredient labels match.
e. All new products and ingredients must be reviewed for food allergens before their initial
use.
Page 19 of 25

2. Cleaning and sanitation procedures.
a. Parts of processing equipment that require manual cleaning should be thoroughly
inspected prior to use.
b. The CIP system must be monitored for proper operation, including time, temperature,
chemical concentration and flow rate. Adjust chemical washes when needed to remove heavy
residues. Document the results from all chemical titrations.
c. Daily equipment inspections should include looking for stuck valves, incomplete
drainage of tanks and improper line hook‐ups.
d. Verify the effectiveness of cleaning and sanitizing. ATP swabs can be used to monitor
surface cleanliness, and milk protein detection swabs can be used prior to manufacturing
non‐dairy products.
3. Prevent cross‐contamination.
a. Allergen containing products should be produced and packaged on separate days
from non‐ allergen containing products. If this is not possible, they should be the last
products run on a production day that also packages non‐allergen products.
b. After processing an allergen containing product the equipment must be cleaned and
inspected prior to use with non‐allergic products.
c. Segregated storage of ingredients and utensils can prevent cross‐contamination.
4. The use of rework should be carefully monitored.
a. Products due to be reworked must be clearly labeled and stored at less than 45°F until
used.
b. Products that contain allergens should only be reworked into products containing
exactly the same allergen.
RECORDKEEPING
1. Records of manufacture list all ingredients and packaging materials as well as their lot numbers.
These are retained for at least two years.
2. Certificates of analysis for ingredients and packaging materials should be obtained from suppliers.
3. Record the results from the cleaner and sanitizer concentration assays on the weekly test form
REFERENCES
1. Berkey Creamery Food Allergen Awareness Plan (most recent revision)

2. SSOP 003 Cross‐Contamination Prevention
Name: ____________________________ Title: __________________________ Date: _______________
Page 20 of 25

SANITATION STANDARD OPERATING PROCEDURE – Labeling, Storage, and Use of Toxic Chemicals
INTRODUCTION
Toxic chemicals are routinely used in all aspects of the food manufacturing process. Proper labeling,
storage and use of these chemicals minimize the chance of finished product contamination as well as
enhance employee safety.
MATERIALS
1. Supplies
a. Gloves
b. Goggles
c. Spill containment supplies
2. Hazards
a. Chemicals can cause damage to skin and eyes.
b. Chemicals used in the manufacturing and sanitation processes are approved for use
in the food industry.
PROCEDURE
1. Labeling:
a. All chemicals, including mixed chemicals, should be properly labeled.
b. Chemical wastes should be labeled with red tags supplied by Environmental Health
and Safety (EHS).
2. Chemical storage:
a. Chemicals should be stored and handled in an area that is dry, well ventilated, and
separate from food handling areas.
b. All chemicals are to be stored so that incompatibles are not next to each other.
c. Chemical wastes should be stored in primary containers that are compatible with the
waste and leak proof. These primary containers should be held in secondary containment in
an approved accumulation area.
d. Stored chemicals must be inventoried annually.
e. Chemicals no longer in use or past their expiration date must be manifested to EHS for
disposal.
3. Chemical usage:
a. Chemical agents, including detergents and sanitizers, should be used in a manner
that prevents contamination of food, packaging materials, and food contact surfaces.
b. Chemicals should be mixed and stored in clean, labeled containers.
Page 21 of 25

4. Training:
a. Chemicals should be handled by properly trained personnel.
b. Within 90 days of hire, all employees that will work with chemicals are required to
attend an initial training provided by EHS. Annual refreshers for that training are mandatory.
c. Material safety data sheets for the chemicals currently in use are located in the CIP room
or they can be accessed on the internet.
RECORDKEEPING
1. Chemical and hazardous waste handling training records will be maintained.

2. Records of the annual chemical inventory will be maintained.
3. A waste review log will be maintained at each accumulation area.
REFERENCES
1. Penn State’s Environmental Health and Safety Office

a. 6 Eisenhower Parking Deck
b. 814‐865‐6391
c. Fax: 814‐863‐7427
d. www.ehs.psu.edu
2. Material safety data sheets
Name: ____________________________ Title: __________________________ Date: _______________
Page 22 of 25

SANITATION STANDARD OPERATING PROCEDURE – Control of Employee Health Conditions
INTRODUCTION
Good manufacturing practices (GMP’s) are established by the Food and Drug Administration and
detailed in the Code of Federal Regulations to protect against contamination of food. GMP’s shall be
followed by all Creamery employees, students, and visitors.
MATERIALS
1. Uniforms or lab coats

2. Shoes or boots
3. Gloves
4. Hair and beard restraints
HYGIENIC PRACTICES
1. Hands are to be thoroughly washed with soap and warm potable water and dried at the following
times, and as needed:
a. When reporting to work
b. After a break period
c. After smoking, eating, or drinking
d. After using toilet facilities
e. At other appropriate times as needed to maintain good sanitation
2. Eating, drinking, and gum chewing are prohibited in food processing areas.
3. Proper hair restraints must be worn
a. Hair restraint must cover entire head, including the front and back
b. Beard restraints must be worn by all employees with more than one day’s growth of
facial hair, including beards, goatees, and sideburns.
c. Mustaches that grow below the lip line must be covered with a beard restraint
4. Fingernails must be properly groomed; clean, cut to an appropriate length, with no polish
or artificial nails.
5. No watches or jewelry, except wedding rings without sets, are permitted in the processing rooms.
6. Smoking and the use of other tobacco products are prohibited, except in designated outdoor areas.
7. Clean uniforms are to be worn at the start of each shift, and left on the premises at the end of each
shift.
a. Uniform shirts and lab coats must have snap closures and no pockets above the waistline.
b. Shoes / boots must remain on the premises and sanitized in a foot bath when appropriate.
c. Hats / bandanas that are worn over hair restraints must be clean and remain on the
premises at the end of the shift.
8. Gloves used in food handling shall be maintained in an intact, clean and sanitary condition.
They should be made of an impermeable material.
9. Personal belongings and street clothing should be stored in an area separate from food handling
areas.
Page 23 of 25

INFECTIOUS DISEASE POLICY
1. Employees affected with any disease capable of being transmitted to others through the
contamination of food, food‐contact surfaces, or food‐packaging materials shall be excluded from any
operations which may be expected to result in the contamination of finished products until the condition
is corrected.
2. Personnel shall report such health conditions to their supervisors.
INJURY / OPEN WOUND POLICY
1. Employees with open sores, bleeding cuts, burns, or skin infections will not be permitted in the
processing rooms.
2. Some hand injuries may be covered with disposable gloves, provided hand washing
procedures are followed.
CONTROLLED ACCESS POLICY
1. Access of personnel and visitors to processing, packaging, and finished product storage areas
should be controlled to prevent contamination.
2. All personnel and visitors must abide by the employee good manufacturing practices listed in the
sections above.
3. All necessary precautions need to be taken to prevent contamination, including the use of foot
and hand sanitizing systems.
PERSONNEL SAFETY PROGRAM
1. OSHA requirements for confined spaces allow access by employees to confined spaces, when
necessary, for matters related to the operation of the processing facility.
2. OSHA rules on injury protection include the installation of devices, such as guards and shields, to
protect personnel from injury. Hearing protection in areas with high levels of operational noise will
reduce hearing related injury.
3. Interior air quality requirements. Adequate ventilation and proper storage of chemicals will
prevent unnecessary airborne exposure to hazardous materials.
REFERENCES
1. Code of Federal Regulations

a. Title 21, Volume 2, Parts 100 – 169 (most recent revision)
2. EPA and OSHA regulations related to personnel safety.
3. Penn State’s Environmental Health and Safety Office
a. 6 Eisenhower Parking Deck
b. 814‐865‐6391
c. Fax: 814‐863‐7427
d. www.ehs.psu.edu
Name: ____________________________ Title: __________________________ Date: _______________
Page 24 of 25

SANITATION STANDARD OPERATING PROCEDURE – Pest Control
INTRODUCTION
A commercial pest control company is contracted to provide pest control services. They provide pesticide
applications on a routine basis for the treatment of insect infestations. Additionally, they perform rodent
control procedures in the building exterior areas as well as areas such as the trash disposal bins and recycling
dumpsters.
MATERIALS
Equipment, supplies, and pesticides are completely under the care, custody, and control of the pest
control company. Pesticides are approved for use in the food industry and the handler is certified and holds
an applicator’s license.
PROCEDURE
Service is performed on a monthly basis. Emergencies are handled promptly and modern equipment is
used. Trained professionals perform services in a safe manner. Concerns and needs are readily addressed and
there are periodic reviews of the pesticide application program.
RECORDKEEPING
All service reports are maintained for at least two years.
Name: ____________________________ Title: __________________________ Date: _______________

Page 25 of 25

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Penn State Berkey Creamery Juice HACCP 2014

Juice HACCP Plan

HACCP Verification Sheet…………………………………………………………………………………… pg.4

Hazard Analysis Summary Table………………………………………………………………………… pg.5

HACCP Plan Summary Table………………………………………………………………………………. pg.6

SOP 002.002 Orange Juice Production…………………………………………………………………….. pg.7

Penn State Berkey Creamery Juice HACCP 2014

Mr. Martin Bucknarage Mr. Thomas Palchak Mr. James Brown

Ms. Bonnie Ford Mr. William Kurtz Ms. Susan Watson

Mr. Terry Grove

BERKEY CREAMERY PRODUCTION AND DISTRIBUTION FLOW DIAGRAM

Product: 100% Pure Florida Orange Juice from Concentrate

Penn State Berkey Creamery Juice HACCP 201

Verification conducted by: __________________________________________

Penn State Berkey Creamery Juice HACCP 201

Berkey Creamery Hazard Analysis Summary Table

Product: 100% Pure Florida Orange Juice from Concentrate

Packaging B Yes Yes: Letter of Guarantee

Berkey Creamery Hazard Analysis Summary Table

Product: 100% Pure Florida Orange Juice from Concentrate

Critical Control Hazards Critical Limits Monitoring Corrective Actions

Critical Control Hazards Critical Limits Monitoring Corrective Action Ve

Penn State Berkey Creamery Juice HACCP 2014

Supersedes SOP: 002.001 Effective Date: 08/25/04

STANDARD OPERATING PROCEDURE – Orange Juice Production

Penn State Berkey Creamery Juice HACCP 2014

Name: ____________________________ Title: __________________________ Date: _______________

Penn State Berkey Creamery Juice HACCP 2014

Supersedes SSOP: 001.001 Effective Date: 10/22/04

SANITATION STANDARD OPERATING PROCEDURE – Water, Steam, and Ice Safety

1. Potable water supply:

Penn State Berkey Creamery Juice HACCP 2014

6. Distilled water supply:

Name: ____________________________ Title: __________________________ Date: _______________

Penn State Berkey Creamery Juice HACCP 2014

SANITATION STANDARD OPERATING PROCEDURE – Processing Equipment Cleaning and

HAND CLEANING PROCEDURE

CLEANED OUT‐OF‐PLACE PROCEDURE

1. Dismantle equipment to be cleaned and rinse with water.

Penn State Berkey Creamery Juice HACCP 2014

OPERATION OF THE RAW CIP CIRCUIT

OPERATION OF THE PASTEURIZED CIP CRICUIT

OPERATION OF THE HTST CIP CIRCUIT

Penn State Berkey Creamery Juice HACCP 2014

CLEANING OF BURNED ON RESIDUE

1. Rinse out residual product.

CLEANING AND SANITATION OF ICE CREAM PROCESSING EQUIPMENT

CLEANING AND SANITATION OF BEVERAGE CONTAINER FILLING EQUIPMENT

Penn State Berkey Creamery Juice HACCP 2014

CLEANING AND SANITATION OF CHEESE PROCESSING EQUIPMENT

1. Cheddar and ricotta vats

Penn State Berkey Creamery Juice HACCP 2014

Penn State Berkey Creamery Juice HACCP 2014

Superseded SSOP: 003.002 Effective Date: 11/27/06

Supersedes SSOP: 003.001 Effective Date: 10/29/04

SANITATION STANDARD OPERATING PROCEDURE – Cross‐Contamination Prevention

Penn State Berkey Creamery Juice HACCP 2014

Penn State Berkey Creamery Juice HACCP 2014

Supersedes SSOP: 004.001 Effective Date: 10/22/04

SANITATION STANDARD OPERATING PROCEDURE – Maintenance of Sanitary Facilities

1. Cleaning equipment and supplies

1. Washrooms, lunchrooms, and changing rooms:

Name: ____________________________ Title: __________________________ Date: _______________

Name: ____________ Title: Date: _

Name: ____________ Title: Date: _

Name: ____________ Title: Date: _

Name: ____________ Title: Date: _

Name: ____________ Title: Date: _

Name: ____________ Title: Date: _

Name: ____________ Title: Date: _