Food Safety, Quality
/ Batching & Processing Traditional Whitemass / Fort Worth, TX
Document Number: 201

Page 1 of 7

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Date Last Update: 2/5/15

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Revision: 6.00

Objective:

The purpose of this procedure is to define proper batching and processing parameters for traditional whitemass according to the formula specifications provided by corporate and available on the R&D Quickr site.

Cautions:

Use only approved utility knives to prevent dropping the knife in the product. Use only approved, heavy duty, blades. Avoid cutting bags while over the opening. Ensure all utensils are stored in a way to prevent accidentally dropping them into the batching system. Do not use breakaway blades. Do not open bags unless approved knives are used and are of approved construction.

Batching Procedure:

Perform the following each time traditional whitemass is batched.

  1. Make sure batch tank is clean and will not exceed the 24-hour time requirements.
  1. Ensure the batch tank to be used is set up for production.
  1. Select ingredient storage (IS) tanks with the oldest milk to batch. Check to make the sure the proteins, butterfat, and solids for the IS milk have been entered into the system.
  1. Enter batch formula, batch number and desired batch size into the system. Record batch tank used on the Traditional Processing QAR Sheet for that product type (Ref: QAR, Doc #219-222, 227 depending on product type).
  1. Go to the recipe manager software and start the batch process. Record batch number on the Traditional Processing QAR Sheet for that product type (Ref: QAR, Doc #219-222,227 depending on product type).
  1. After all milk has been transferred into the batch tank from IS, take a “milk only” sample and test the proteins and butterfat. Record on the Traditional Processing QAR Sheet for that product type (Ref: QAR, Doc #219-222, 227 depending on product type). See the recipe manager software for acceptable ranges. If the above information is not within range, see the attached decision grid (Figures 1A and 1B).
  1. Examine the exterior of ingredient bags and/or storage containers. Remove all loose objects such as stretch wrap, tape, and all foreign materials. If bag is torn or the condition is not acceptable, place on HOLD following the Placing Raw Materials on Hold procedure (Ref: SOP, Doc #18).
  1. If all parameters are conforming, start recirculation and add the dry ingredients according to the order listed in the recipe manager:
  1. Weigh all dry ingredients to the nearest pound. Partial bags of ingredients are to be stored in the labeled plastic drums provided. DO NOT dump ingredients into the drum.
  1. Record all ingredient lot numbers and enter into the system.
  1. Begin hydration, checking to ensure the hydration timer is set for 30 minutes after all ingredients have been added. When hydration is complete, pull a sample from the batch tank and test sample for total solids according to the Operation of CEM (Ref: SOP, Doc #724) procedure. Record result on the Traditional Processing QAR Sheet for that product type (Ref: QAR, Doc #219-222, 227 depending on product type). If results are not within the range according to the recipe management software, see the attached decision grid.
  1. When batching is complete, enter/record all required information in/on the appropriate systems and/or documents and begin processing whitemass to the buffer vat.
  1. Record the pounds of whitemass in the batch tank on the Traditional Processing QAR Sheet for that product type (Ref: QAR, Doc #219-222, 227 depending on product type).

Batch to Buffer Vat Procedure:

Perform the following each time a batch of traditional whitemass is processed from the batch tank to the buffer vat through HTST #1.

  1. Make sure HTST has been CIP’ed, sterilized and is within the 24-hour time requirements. See the applicable Processing CIP Form (Ref: QAR, Doc #252-A) for this information.
  1. Ensure there is an available buffer vat to transfer whitemass into and that it is set up for production. Make sure the tank meets regulatory requirements.
  1. Confirm the batch proteins, butterfat, and solids are compliant before beginning transfer. See the Traditional Processing QAR Sheet for that product type (Ref: QAR, Doc #219-222, 227 depending on product type) or Table 1 for this information.
  1. Go to the appropriate software and begin the process to transfer the batch. Record buffer vat batch is processed into on Traditional Processing QAR Sheet for that product type (Ref: QAR, Doc #219-222, 227 depending on product type).
  1. When batch has begun processing, walk the system lines to ensure the lines and/or valves are not leaking and are functioning properly. If they are leaking or improperly functioning, see the decision grid (Figures 1A and 1B).
  1. Monitor the system to ensure all proper parameters are being met such as the HTST Temperature, the Homo PSI, the Regen Temperature and the Buffer Vat Temperature. Record on the Traditional Processing QAR Sheet for that product type (Ref: QAR, Doc #219-222, 227 depending on product type). See the decision grid (Figures 1A and 1B) if they are not within range.
  1. Check the indicating temperature and the recording temperature during pasteurization. Document as necessary on the required charts. If the indicating temperature is lower than the recording temperature, notify supervisor for further directions.

If using MIF inoculation, continue with step 8. If NOT using MIF inoculation, skip to step 11.

  1. When the MIF reaches step 6 and prompted by automation for the corresponding buffer vat, get the required type(s) and amounts of cultures from the culture freezers according to Table 1.

Table 1

  1. Refer to Processing SOP document # 206 for culture carton sanitation.
  1. Record the amounts used and lot numbers for each culture type, using military time, record the time that the buffer vat was inoculated on the, record the amount transferred into the buffer vat, check to make sure the tank has the appropriate sterile air overpressure (PSI). Record on the Dannon Creamy Processing QAR Sheet (Ref: QAR, Doc # 203).
  1. Record the amount transferred into the buffer vat on Traditional Processing QAR Sheet for that product type (Ref: QAR, Doc #219-222, 227 depending on product type).
  1. Check to make sure the tank has the appropriate sterile air overpressure (PSI). Record on Traditional Processing QAR Sheet for that product type (Ref: QAR, Doc #219-222, 227 depending on product type).
  1. When transfer is complete, pull two (2) samples from the buffer tank with separate syringes.
  1. With one sample, analyze % protein, % butterfat and % solids according to the Operation of the Milk-o-Scan (Ref: SOP, Doc #718) procedure. Record results on Traditional Processing QAR Sheet for that product type (Ref: QAR, Doc #219-222, 227 depending on product type). If results are not in range according to the recipe management software, see the decision grid (Figures 1A and 1B).
  1. Label the other syringe with the batch #, buffer vat #, whitemass type, date and MICRO. Place sample in refrigerator in processing control room for micro analysis by QA. Circle yes or no on the Traditional Processing QAR Sheet for that product type (Ref: QAR, Doc #219-222, 227 depending on product type), indicating that the micro sample was pulled and that the needle is still intact. If needle is not intact, immediately notify supervisor.

Buffer Vat to Filler Procedure:

Perform the following each time a batch of traditional whitemass is sent to the filler for production.

  1. Make sure culture has been batched and processed according to the Batching and Processing Culture (Ref: SOP, Doc #205) procedure and that the culture is <12 hours after inoculation.
  1. Make sure the filling lines are clean and compatible and are within the 24-hour CIP or the 48-hour production time requirements.
  1. Sterilize the buffer tank outlet following the Steam Sterilization of Processing Equipment (Ref: SOP, Doc #257) procedure.
  1. Confirm the type of whitemass that the filler is requesting is the proper whitemass according to the production schedule.
  1. Selecting the correct buffer vat, culture vat, and filler, send whitemass and culture to filler and verify the transfer has begun. Record the transfer time and the selected culture vat on the Traditional Processing QAR Sheet for that product type (Ref: QAR, Doc #219-222, 227 depending on product type).
  1. During transfer, walk the system lines to ensure the lines and valves are not leaking and are working properly.



Figure 1B