PROCEDURE FOR BUTTER PROCESSING

1. PURPOSE
The purpose of this procedure is to ensure that butter processing is carried out in
accordance with GDFCS quality management system.

2. SCOPE
This procedure covers processing of butter intended for final packaging in tubs,
wrappers, bulk or for ghee processing.
3. RESPONSIBILITY
The production manager is responsible for implementation of this procedure.

4. REFERENCE DOCUMENTS
Butter production document (Bp-01)
QA-B01) record book

5. DEFINITIONS
Pasteurization-Heat treatment aims at destroying pathogens (85-90 0C for 30
minutes)
Aging of cream-Holding at low temperature (8-10 0c) for (8-12hrs) to allow
Conglomeration of fat globules for easy churning.
Chilling-cooling to below 10 0c
Churning-continuous agitation to break the concentrated water in oil emulsion
(Cream) into butter grains and butter milk.

6. PROCEDURE
6.1 The personal hygiene of the operator shall be maintained at high levels during
processing and packaging.
6.2 The operator shall ensure that good manufacturing practices are maintained
through out processing.
6.3 The operator shall prepare the batch pasteurizer as per work instructions and
maximum processing temperature set at 85-95 0c).
6.4 The operator shall introduce standardized good quality cream analyzed by
quality control staff into the batch pasteurizer.
6.5 The cream shall be pasteurized at 85-90 0C / 30min with continued agitation.
6.6 Pasteurized cream shall be transferred aseptically into clean cans.
6.7 Cream shall then be chilled to below 100C immediately and aged for 8-12 hrs.
6.8 The operator shall clean the churn and cleanliness audit shall be done by the
laboratory assistant.
6.9 Aged cream shall then be churned followed by washing using chilled
pasteurized water and finally worked on.

6.10 After working a sample of butter shall be submitted to the laboratory for
analysis.
6.11 If the results are ok, the operator shall ascetically pack and transfer it to
the freezer room for storage. If the results are not ok then the butter made shall
be used to make ghee.
6.12 The operator shall continuously record the occurrences and an output
which shall be verified by the shift production clerk and counter signed by the
production supervisor.

PROCEDURE FOR GHEE PROCESSING

1. Purpose:
The purpose of this procedure is to ensure that ghee processing is carried out in
accordance with the requirements of G.D.F.C.S quality management system

2. Scope:
This procedure covers processing of ghee from cream aging to its packaging.

3. Responsibility:
The production manager is responsible for implementation of this procedure.

4. Reference documents
-Quality assurance standard-06(QA STD-06)
-QA-CIOI STD
-Quality assurance test methods manual

5. Definitions:
Pasteurization-Heat treatment aimed at destroying pathogens (85-950C)
Aging of cream- Holding at low temperatures (8-100C) for (8- 12 hrs) to
allow initial cogeneration of fat globules for ease of churning.
Churning- Continuous beating and agitation to break the concentrated oil in
water emulsion (cream) into butter grains and butter milk.

6. PROCEDURE
6.1 The personal hygiene of the operator shall be maintained at high levels
During processing.
6.2 The operator shall ensure that good manufacturing practices are maintained
throughout processing.
6.3 The operator shall then fill quality standardized (42% butter fat) raw cream
into milk cans.

6.5
6.6
6.7
6.8
6.9

The cream shall be chilled to 8-10 0C immediately and aged for 8-12 hrs.
Aged cream shall then be churned (150liters for 40 minutes) and butter milk
drained.
Butter shall then be heated gently to 110-115 0 C for 5-6 hours to obtain
golden yellow colour.
A sample of ghee shall be taken to the laboratory for analysis.
Ghee shall then be cooled to 40 0 c, filtered and fine ghee packed aseptically.
The operator shall record the occurrences in the O.B as well as the output
which shall be verified by the production clerk and countersigned by the
Production supervisor.

PROCEDURE FOR YOGHURT PRODUCTION

1. PURPOSE
This procedure ensures that treatment of milk base intended for stirred yoghurt
production is carried out in accordance with GDFCS ltd quality management system.

2. SCOPE
This procedure covers processing of stirred yoghurt from raw milk selection up to
packaging.

3. RESPONSIBILITY:
The production manager is responsible for implementation of this procedure.
4. REFERENCES:
-Yoghurt production form (YMP:02)
-QC STD-04

5. DEFINITIONS:
Pasteurization-heat treatment aimed at destroying pathogas (85-90 0c)
Inoculation-Addition/introduction of starter culture
Incubation-holding of a specific temperature(40-43 0c) without disturbing to allow
fermentation to take place
.
Homogenization-Breaking of fat globules in milk to avoid creaming after
pasteurization to improve on phial attributes.
Clarification-removal of fine dirt from milk through centrifugal force and eventual
discharge into the drain.
Separation- Removal of butter fat from milk through the separator

6. PROCEDURE
6.1.0: The personal hygiene of the milk processing and yoghurt processing operator
shall be maintained at high levels during processing and packaging.
6.1.2: The milk and yoghurt processing and operators ensure that the PHE and
yoghurt batches are cleaned as per GDFCS cip / cop work instructions.
6.1.3: High quality raw milk from selected routes shall be analyzed and conforming
milk chilled and isolated to a specific tank and its quality continuously monitored by
the Laboratory assistant.
6.1.4 : The isolated raw milk shall be introduced into the P.H.E with pasteurization
temperatures stabilized at 78-80 0c and homogenization pressure set at 100-150 bars.

6.1.5: Pasteurized and homogenized milk shall be projected into the batch
pasteurizers.
6.1.6: The operator shall then raise the temperatures of milk is to 50-60 0c and use it
to make slurry using sugar and stabilizer at predetermined ratio. For the natural and
real fruit yoghurt, only skim milk powder shall be used to make slurry.
6.1.7: The operator shall thereafter add the slurry into the milk in the batches while
agitating gently.
6.1.8: The mixture shall further be heated to 85-90 0c for 30 min with continued
agitation.
6.1.9: The mixture shall then be cooled to 40-43 0c and a sample taken to the
laboratory for microbiological/Bacteriological analysis.
6.2.0: Hemophilic lactic culture shall then be inoculated aseptically (50 lt in
500lts) and agitated for 10 min.
6.2.1: The mixture shall then be incubated for 4-6 hrs at 40 43 0C.
A sample shall be taken to the lab after six hour to monitor acid development.
6.2.2: The Coagulum shall be broken after achieving 0.70% lactic acid and cooled
to<20 0c A sample is taken for bacteriological and Organoleptic testing.
6.2.3: Flavoring and colouring shall then be done as per the product range and at
predetermined rate. For the real fruit yoghurt, real fruit concentrate shall be added
while for the natural yoghurt, there shall be neither flavouring nor colouring.
6.2.4: Product shall then be aseptically packaged and stored at 2-4 0c.
6.2.5: The operator shall record the occurrences in the O.B as well as the output
which shall be verified by the production clerk and countersigned by the
Production supervisor.

PROCEDURE FOR LALA PROCESSING

1. PURPOSE:
This procedure ensures that treatment of milk base intended for lala production is
carried out in accordance with GDFCS ltd integrated quality management system.

2. SCOPE:
The procedure covers processing of the lala intended for direct consumption.

3. RESPONSIBILITY:
The production manager is responsible for implementation of this procedure.

4. REFERENCES:
-QC STD-04
-Lala milk production form (LMP: 01)

5. DEFINITIONS:
-Pasteurization-Heat treatment aimed at destroying pathogas (85-90 0c).
-Inoculation-Addition of starter culture.
-Incubation-Holding at specific temperature (20-24 0c) without disturbing to allow
fermentation to take place.
-Homogenization-Breaking of fat globules in milk to avoid creaming after
pasteurization to improve on physical attributes.
-Clarification-Removal of butter fat from milk through the separator.

6. PROCEDURE:
6.1: The personal hygiene of milk processing and lala processing operator shall be
maintained high at all levels during processing and packing.
6.2: The milk processing and lala processing operator ensures that the PHE and lala
incubation tanks are well cleaned respectively.
6.3: High quality raw milk from selected routes shall be analyzed and conforming
milk chilled and isolated to a specific tank and its quality continuously monitored by
the Laboratory assistant.
6.4: The isolated milk shall be introduced into the PHE and pasteurized at 85-90 0c
for 5-7 min and homogegenised at 100-500 bars.
6.5: Pasteurized milk shall be directed into lala incubation tanks and temperature
controlled by regulative cooling to 20-24 0c

A sample of pasteurized milk shall thereafter be taken for bacteriological and

chemical analysis.
6.6: Hemophilic lactic culture shall then be aseptically inoculated into the milk 950 u
in 500lts) and agitated for 10 min. A sample shall then be taken to the laboratory for
analysis.
6.7: The milk shall be incubated for 8-16 hrs and acidity development monitored from
the eighth hour and at the same time ensuring that the coagulum is not disturbed at
all.
6.8: coagulum shall be broken after attaining 0.7% lactic acid and cooled to below10
0
c.A sample shall be taken for bacteriological and organolyethc testing in the
laboratory.
6.9: Product shall be packed aseptically and transferred to cold storage at 2-4 0c.
6.10: The operator shall record the occurrences in the O.B as well as the output
which shall be verified by the production clerk and countersigned by the Production
supervisor.