PROCESS CONTROL
1. Raw Material Control
Milk Quality Control: Outline procedures for testing the raw milk used. Key
parameters include:
o Microbial Load: Regular testing for pathogens like Listeria,
Salmonella, and E. coli.
o Somatic Cell Count (SCC): Indicator of mastitis in cows, affecting
milk quality.
o Fat and Protein Content: Ensuring consistent cheese yield and
texture.
o Antibiotics and Contaminants: Milk should be tested for residues
that could impact cheese quality or consumer health.
o Temperature Control: Ensure milk is stored and handled at
appropriate temperatures (below 5°C) to prevent spoilage.
2. Cheese Production Process Control
Standard Operating Procedures (SOPs): Detail specific controls for each
step in the production process, including:
Cheese Milk Preparation
Fat Standardization: Adjust fat content relative to solids-not-fat (SNF),
specifically casein. The ratio of fat to SNF (casein) is crucial for cheese
texture and yield consistency.
o Control Point: Ensure proper fat content for the cheese type being
produced to achieve the desired texture and quality.
Pasteurization (optional):
o Temperature: Heat the milk to 70-72°C for 15-20 seconds (if
employed).
o Critical Control Point (CCP): If pasteurization is performed, time
and temperature must be carefully controlled and recorded to eliminate
pathogenic bacteria.
o Cooling: Reduce milk temperature to approximately 30°C to prepare
for renneting.
Mechanical Bacteria Reduction (optional)
Microfiltration: This method can mechanically reduce bacteria to further
enhance milk safety before cheesemaking.
o CCP: Effective filtration or separation to reduce contamination risk.
In the Cheese Vat
Conditioning of Cheese Milk:
o Additives:
Calcium chloride: Improves curd formation by enhancing
coagulation.
Saltpetre (nitrate): Used in some cheeses, subject to local
laws.
Starter bacteria: Appropriate cultures based on the type of
cheese being produced.
Rennet: The enzyme used to coagulate milk into curds.
CCP: Monitoring the correct quantities and types of additives
(e.g., ensuring compliance with legal limits on saltpetre).
Coagulation (Curd Formation):
o Coagulum: The formed curd is cut into smaller grains to release whey.
o Control Point: Ensure that curd cutting is done uniformly to manage
moisture content.
Whey Removal:
Part of the whey is drained from the curds to begin cheese formation.
o Control Point: Ensure the correct amount of whey is removed for the
type of cheese being produced.
Washing the Curd (for semi-hard cheeses):
o Water Addition: Washing the curd with water affects acidity and
texture. Typically done for semi-hard cheeses.
o Control Point: Control temperature and quantity of water for desired
cheese characteristics.
Molding and Pressing: Define pressure levels and duration for pressing
cheese into desired shapes.
o Ensure uniform texture and prevent air pockets.
Ripening/Aging: Monitor storage conditions (temperature, humidity) to
ensure optimal aging.
o Regular checks for mold growth, pH changes, and flavor development.
PROCESS FLOW CHART
3. Cleaning and Sanitation
CIP (Clean-in-Place) Procedures: Document cleaning schedules and
sanitizing procedures for all equipment.
Environmental Monitoring: Regular swabbing and air quality checks in the
production facility to prevent contamination.
4. Packaging and Storage Control
Packaging Materials: Use food-grade materials that maintain cheese quality
and prevent contamination.
Labeling: Ensure labels meet regulatory standards for nutritional information,
batch number, and expiration dates.
Cold Chain Management: Maintain storage temperatures (typically 1-5°C
for fresh cheeses, 10-12°C for aged cheeses) to ensure quality and shelf life.
5. Final Product Testing
Sensory Evaluation: Test for consistency in texture, flavor, aroma, and
appearance.
Microbiological Testing: Perform routine tests for pathogens and spoilage
organisms.
Chemical Analysis: Regularly check for moisture content, fat, salt, and pH to
ensure batch consistency.
6. Traceability and Record Keeping
Keep detailed logs of raw materials, production batches, and product testing to
trace any issues back to their source. Include:
o Supplier details for raw materials.
o Batch records for each stage of production.
o Results of quality checks and corrective actions if necessary.
7. Corrective Actions
Establish a plan for addressing deviations in the process (e.g., out-of-spec
products).
Define procedures for identifying, isolating, and investigating non-conforming
products.
8. Personnel Training
Provide regular training for staff on food safety, hygiene, and quality
assurance.
GOOD MANUFACTURING PRACTICES (GMP)
Requirement Non-conformity Corrective Measure
Building and
Installation
Presence of unused Remove unused equipment; close
External area equipment, insects, and access for animals; implement pest
domestic animals. control by a specialized firm.
Renovate the industrial area;
Cracked floors, whey
properly channel whey discharge;
Internal area accumulation, unused
organize and store materials
materials in the ambient.
appropriately.
Lack of toilet paper, liquid
Sanitary installations Change supplier for towels; install
soap, and correct
and cloakrooms handwashing instructions.
handwashing instructions.
Ventilation and
Acclimatization
Production area Inadequate ventilation. Install exhaust systems.
Water Supply
Implement procedures and records
No records of chlorination
Potability for water chlorination and pH
or pH control.
testing.
Reference List
1. Dairy Processing Handbook, Chapter 14, Cheese.
2. Dias, M. A. C., Sant’Ana, A. S., Cruz, A. G., Faria, J. A. F., de Oliveira, C. A. F., & Bona, E.
(2011). On the implementation of good manufacturing practices in a small processing unit of
mozzarella cheese in Brazil. [Journal Name], [Volume], [page numbers].
https://doi.org/[DOI]
