The FSSAI has developed a scheme for sampling and testing and inspections to be adopted by dairy processing plants for the purpose of self-monitoring and strengthening of internal controls. This has been developed as a result of the National Milk Safety and Quality Survey (NMQS) conducted by FSSAI in 2018 which showed high level of non-compliance in quality as well as safety parameters in standardised processed milk. This suggests that internal systems of monitoring safety and quality are deficient either due to faulty design or lax implementation which needs to be addressed.
The FSSAI has decided that the dairy processing plants should follow a standardised Scheme of Sampling, Testing and Inspection (Annexure 1 given below) for the monitoring of internal controls to ensure safe and good quality supply of milk and milk products to consumers. This scheme will be effective from 1 January, 2020. All dairy processing plants shall maintain appropriate records in this context which would be verified during surveillance visits/inspections.
SCHEME FOR SAMPLING. TESTING AND INSPECTION FOR DAIRY PROCESSING PLANTS
The Scheme for Sampling, Testing and inspection for dairy processing plants developed by FSSAI has to be implemented at all dairy processing establishments as per the frequency mentioned in the FSSAI documents. The establishments shall also ensure that the samplers have adequate knowledge of sampling of raw and processed milk the raw and processed milk from different locations as per the scheme.
The scheme stipulates the sampling points, test methods, frequency of sampling and permissible limits as per FSSR. The establishment may consider to increase the sampling points and sampling frequency as per their requirement with respect to capacity and production process.
The dairy processing establishments shall have a well-equipped in-house laboratory for testing microbiological and other chemical parameters. The testing shall be done by qualified and trained laboratory personnel. In case of unavailability of in-house facilities for test parameters that require advanced analytical equipment, the tests may be carried out at FSSAI notified lab. The details of FSSAI notified labs are available at www.fssai.gov.in.
The establishments shall maintain all the test records at least for a period of one year in addition to the documents and records listed in Part 3 of Schedule 4 of Food Safety and Standards (Licensing and Registration) Regulations, 2011. The results of all such tests shall be made available to the official of Food Authority or Food Safety Commissioner for verification as and when required.
In case any non-compliance is reported and deviation can be corrected without affecting the safety and quality of milk, then it should be re-processed and again tested to ensure that re-processed milk conforms to all the requirements. However, if there is a non-compliance on parameters which can not be corrected even by re-processing like presence of residues, adulterants, etc, the entire batch shall be rejected. In case its already under process, then production shall be stopped immediately. The production shall be resumed only after carrying out root cause analysis for the non-compliance, corrective and preventive action is taken and its effectiveness verified during subsequent testing. The records of all such investigation shall be maintained.
Any rejected material which is potentially re-saleable shall be destroyed or disposed off in such a manner that it cannot be used for any other purpose. A separate record shall be maintained giving information on quality and batch no. as applicable, relating to all such rejections/defective/sub-standard material of the production not conforming to the requirements and the methods of its disposal. Such material shall in no case be stored together with that conforming to the specification.
The scheme document, format of reporting and minimum lab facility/equipment required to establish in-house testing facility at raw milk reception dock in annexed.
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SCHEME OF TESTING AND INSPECTION FOR MILK |
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INSPECTION/ TEST METHOD |
INSPECTION/ TEST METHOD * |
SPECIFICATION LIMITS |
INSPECTION POINT |
TESTING FREQUENCY |
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Physical/ Chemical /Compositional Parameters |
|
Raw milk reception/ Release (Raw milk can/milk tanker) |
Standardization/ Pasteuri zation (Silo/ Milk Storage tanks) |
Filling (Filling Area) |
Finished Good/ Products (Pouch/ Despatch milk tanker) |
Raw Milk |
Proc essed Milk |
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1 |
Seal |
Visual Inspection |
Ok |
ü |
ü |
|
ü |
Each Tanker |
every batch Or silo or hourly in case of continuous line.
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2 |
Appearance |
Visual Inspection |
White to cream colour, odour typical of fresh milk |
ü |
ü |
|
ü |
Every tanker/ container |
every batch Or silo or hourly in case of continuous line.
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3 |
Taste and Flavour (organoleptic evaluation) |
Sensory Evaluation |
Satisfactory |
ü |
ü |
|
|
Every tanker/ container |
every batch Or silo or hourly in case of continuous line.
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4 |
Foreign matter |
Visual inspection/ Filteration |
Absent |
ü |
ü |
|
|
Every tanker/ container |
every batch Or silo or hourly in case of continuous line.
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5 |
Temperature |
Thermo meter |
At max 6deg |
ü Only raw chilled milk |
ü |
ü |
ü |
Every tanker/ container |
every batch Or silo or hourly in case of continuous line.
|
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6 |
Fat |
Chemical extraction, Gerber Method, electronic |
Specified as per FSSR |
ü |
ü |
ü |
ü |
Every tanker/ container |
every batch Or silo or hourly in case of continuous line.
|
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7 |
SNF |
Density, Gravimetric, electronic |
Specified as per FSSR |
ü |
ü |
ü |
ü |
Every tanker/ container |
every batch Or silo or hourly in case of continuous line. |
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8 |
SMP (for species identified milk and mixed milk) |
Chemical |
Negative |
ü |
|
|
|
Every tanker/ container |
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9 |
Acidity |
pH, Titration |
Min 0.10% Max 0.15% (as lactic acid), pH 6.5-6.8 |
ü |
ü |
ü |
ü |
Every tanker/ container |
every batch Or silo or hourly in case of continuous line.
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Adulterants |
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|
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|
|
|
|
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10 |
Cellulose |
Chemical |
Negative |
ü |
ü |
ü |
|
Every tanker/ container |
every batch Or silo or hourly in case of continuous line.
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11 |
Starch |
Chemical |
Negative |
ü |
|
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|
|
– |
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12 |
Formaline, H2O2 Boric acid |
Chemical (Hehners Test) electronic |
Negative |
ü |
|
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Every tanker |
– |
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13 |
Detergents/Caustic Soda |
Chemical, electronic |
Negative |
ü |
|
|
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Every tanker |
– |
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14 |
Vegetable oil/Fat |
Chemical ,electronic |
Negative |
ü |
|
|
|
Every tanker |
– |
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INSPECTION CHARACTERISTIC |
INSPECTION TEST METHOD |
SPECIFICATION LIMITS |
INSPECTION POINT |
TESTING FREQUENCY |
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|
Physical /chemical / Compo sitional Parameters |
|
Raw milk reception/ Release (raw milk can/tanker |
Standardi sation Pasteuri sation (silo/ milk storage tanks |
Filling (filling area) |
Finished goods/ Products Pouch/despactch Milk tanker |
Raw milk |
Processed milk |
|
15 |
maltodextrin |
Chemical |
Negative |
ü |
|
|
|
Every Tanker |
|
16, |
Dextrose (glucose) |
Chemical (diastix) electronic |
Negative |
ü |
|
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|
Every Tanker |
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17. |
Urea |
Chemical Electronic |
700mg/kg |
ü |
|
|
|
Every Tanker |
|
18. |
Sucrose (cane sugar) |
Chemical Electronic |
Negative |
ü |
|
|
|
Every Tanker |
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19. |
Salts (NaCl KCI) |
Chemical Electronic |
Negative |
ü |
|
|
|
Every Tanker |
|
20. |
Neutralizer (carbonate Bicarbonate Percarbonate
|
Chemical Electronic |
Negative |
ü |
ü |
ü |
ü |
Every Tanker |
Every Batch or silo |
21. |
Nitrates |
Chemical Electronic |
Negative |
ü |
|
|
|
Every Tanker |
|
22. |
Ammonium sulphate |
Chemical
|
Negative |
ü |
|
|
|
Every Tanker |
|
|
Chemical contaminants |
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23. |
Pesticides Reside (With Isomers) |
Chemical, chromatographic,electronic |
Specified as per FSSR |
ü |
|
|
|
Every 3 months from each supply source |
– |
24. |
Antibiotic Veterinary Drugs residues |
Beta Lactam (Delvotest) |
Specified as per FSSR |
ü |
|
|
|
Weekly from each supply source |
– |
25. |
Aflatoxin MI. max |
Chemical, chromatographic, electronic |
0.5 µg/Kg |
ü |
|
|
|
Every 2 months from each supply source |
– |
26. |
Melamine |
chemical |
Specified as per FSSR |
|
ü |
|
|
Every month from each supply source |
– |
|
Microbiological Contaminant |
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27.. |
MBRT |
Dye reduction |
Min 30 minutes for raw chilled milk & min 5 Hrs 30 mts for pasteurised milk |
ü |
|
|
|
Every Tanker |
Every batch or Silo in case of continuous line |
28. |
phosphates |
Chemical, Dye reduction |
NA |
|
ü |
|
|
– |
Every batch or Silo in case of continuous line |
29 |
PC/ml** |
Pour plate method, electronic |
|
ü |
|
|
ü |
Every Tanker/ Container |
Every batch or Silo in case of continuous line |
30. |
Coliform/ml** |
Pour plate method, electronic |
|
ü |
|
|
ü |
Every Tanker/ Container |
Every batch of Silo or hourly in case of continuous line |
SCHEME OF TESTING AND INSPECTION FOR WATER SUPPLY FOR DAIRY PROCESSING UNIT (As per IS 4251) |
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31 |
Taste & Odour |
Sensory evaluation |
Free from objectionable taste and odour |
|
Every 6 months |
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pH |
pH meter |
6.5-9.2 |
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TDS |
pH meter |
1000 mg/ 1 max |
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Hardness |
TDS meter |
600 mg/1 |
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Chloride |
Titration |
250 mg/1 max |
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Coliform/100ml |
Titration |
Less than 1 MPN |
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SPC/ml |
Membrane filteration method/ MPN method |
50 |
Note: “FSSAI manual of Methods of Analysis for Milk and Milk Products and any other appropriate method which includes BIS test method. FSSAI approved Rapid kit or test methods as applicable.
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