الفهرس 
INTRODUCTIONOnly 14 pages are availabe for public view
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Abstract
The safety of dairy products with respect to food-borne diseases is a great concern around the world. This is particularly true in countries where production of milk and various dairy products take place under unsanitary conditions and poor production practices.
Food safety in food industries, requires compliance with the basic requirements of codes of good hygiene practices or prerequisite programs (PRPs), along with a food safety management system (FSMS) such as HACCP and ISO 22000. FSMS have an important contribution to the achievement of food safety and quality. ISO 22000:2018 can be used by all the direct and indirect food chain stakeholders, regardless of their size or their location and it covers the food supply chain from the primary production to consumptions. It helps organizations to identify and control food safety hazards. The benefit to improve health and safety through minimizing the food risks, to meet the regulatory requirements, to improve customer satisfaction and to increase response to risks.
The purpose of this study is to implement FSMS ISO 22000:2018 in a dairy products plant in Gaza strip, Palestine.
To fulfill this objective, the study was conducted in 3 phases.
Phase I: (Pre-implementation): This phase included:
1. Assessment of PRPs in the plant before implementation of ISO 22000:2018: using a pre-structured checklist through observation of the 14 PRPs parameters.
2. Assessment of hygienic condition of the dairy products (from each processing step for yogurt and cheese production), water supply and swabs from dairy plant processing surfaces, worker`s hands, and from the packaging materials before FSMS ISO22000:2018 implementation through physical, chemical and microbiological analysis of samples in relation to requirement of Palestinian Standards.
Phase II: (Implementation):
Implementation of FSMS ISO 22000:2018 in the dairy products plant through applying the following recognized elements: Interactive communication; Principles of ISO management system standard; Pre-requisite programs PRPs establishment and Hazard Analysis Critical Control Points (HACCP) application according to ISO 22000:2018 standard.
Phase III: (Post Implementation): Evaluation of the effectiveness of the implemented FSMS ISO 22000:2018 through:
1. Assessment the conformity of the designed and implemented food safety management system with the requirements of ISO 22000:2018 standard using a specially designed ISO auditing checklist that cover all the required clauses of ISO 22000:2018 (context of the plant, leadership, planning, support, operation, performance evaluation & continual improvement).
2. Assessment of hygienic condition of dairy products, water supply and swabs from dairy plant processing surfaces, worker`s hands, and from the packaging materials after implementation of ISO22000:2018.
The results of this study revealed the following:
Phase I: Pre implementation of FSMS ISO 22000:2018
• The overall score percentage of the available required elements of the PRP was fair (60.2%), and 39.8% of the PRP requirements were absent.
• The highest score percentage among the present PRP was in product information and consumer awareness (100%), while a poor level was observed regarding Environment & Location (28.6%) & Utilities –air, water, and energy (46.66%). The deficiency in PRP were more pronounced in the pest control and product recall procedures (100% each).
• After rehabilitation, the overall score percentage of PRPs parameters were improved to 95.5%. The score percentage of waste disposal, equipment suitability, cleaning and maintenance, management of purchased materials, measures for prevention of cross-contamination, cleaning and sanitizing product recall procedures, warehousing, training, increased to 100%. Also, the score percentage of pest control parameter increased to 85.7%..
• Regarding the physical properties of raw milk and dairy products (yogurt & cheese), it was within the acceptable level of the Palestinian standards.
• All the chemical properties including the values of fat, solid matter, NFS, pH, and acidity of raw milk, yogurt and cheese, and moisture and Nacl for cheese were complied with the Palestinian standards except the fat % for raw milk (2.01%) did not comply with P.S. for raw milk which is (≥3%).
• Raw milk, yogurt and cheese were free from any pesticides and antimicrobial drug residues. While heavy metal contaminants were within the maximum allowed concentration (MAC).
• Regarding Microbiological analysis along yogurt processing chain, the mean value for aerobic psychrotrophic count, aerobic mesophilic count, total coliform, E. coli, yeast, Staphylococcus aeurus and Campylobacter spp. counts for the raw milk samples were 5.1x105CFU\g, 9.7x105 CFU\g, 5.4x105 MPN\g, 6.0x103 MPN\g, 4.2x105CFU\g, 2.5x103 CFU\g and 3.7x10² CFU\g, respectively. The mean value for aerobic mesophilic count, total coliform, and E. coli counts for the end yogurt product samples were 1.5x10⁴CFU\g, 6.2x10ᶾ MPN\g, 2.2 x10ᶾ MPN\g, respectively, on the other hand mold, salmonella spp, and listeria spp. was not detected.
• For Microbiological analysis of finished cheese product, The mean value for aerobic psychrotophic count and aerobic mesophilic count was 2.3x10² CFU/g, 2.0x10⁴ CFU/g, respectively, while, mold, salmonella spp, and listeria spp. was not detected.
• Regarding the physical and chemical analysis of water supply in plant, the concentrations of the all tested chemical elements were within the range of Palestinian standard limits except the free Chlorine level (0.12 ±0.2 mg/L) which was lower than the Palestinian limits (0.2 mg/L).
• Microbial limits of potable water were not complied with Palestinian standard for drinking water where the mean value of total coliform and fecal coliform were 6.8 and 0.8 colony/100 ml, while, after water treatment by chlorination using DE chlorinating substance (sulfuric acid), the total coliform counts and the fecal coliform were absent.
• For Microbiological examination of swab samples, the mean value of total viable count was the highest among plant`s processing surfaces (1.3 x 10ᶾ CFU/cm²) while the lowest value was among the packaging material (7.7 x102 CFU/cm²). on the other hand, the mean value of coliforms was (5.1x10 MPN/cm², 9MPN/cm²) for the processing surfaces and packaging material respectively, and it was not detected in the worker`s hands. While fecal coliform was absent in all swab samples. Regarding staphylococcus aureus count, the mean value was (2.1 x 10² CFU/cm²) among the worker`s hand and plant`s processing surfaces each, while it was the lowest among the packaging material (6.3 x 10 CFU/cm²).
Phase II: Implementation of FSMS ISO 22000:2018
• Internal (between employees) and external (supplies, customers, services contractors and regulatory authorities) communications were established in the plant, and communication records were maintained& documented.
• Top management provided its commitment to implement and update FSMS ISO 22000:2018, through developing the context of dairy product plant, scope, its interested parties, their needs and expectations, defining policy and objective.
• Food safety team was assigned, and their roles and responsibilities were identified.
• Adequate resources were identified.
• Emergency preparedness and response procedures were established and documented.
• Withdrawal and recall procedures were established and documented.
• Internal audit plan was conducted to evaluate the system compliance.
• Management reviews were conducted and documented its input and outcome to evaluate the performance of the implemented system.
• The characteristics of raw material, ingredients and packaging material used in processing chain of dairy products were descried. Also, the end products were described with their intended use, and instruction for proper storage and distribution.
• Flow diagram and process description for each dairy product (yogurt and cheese) were established & documented from raw material to the end product.
• All food safety hazards were identified through listing all expected food safety hazards along yogurt and cheese processing plant and determination of their acceptable level.
• For hazard assessment, each identified hazard was assessed according its severity and its probability of occurrence using the five-point system (5 × 5) and a weighted point rating system for each dairy products and its significance was recorded as significant if scored ≥10 and controlled by OPRPs or HACCP/CCP, while, the non-significant hazard scored <10 managed as PRP.
• As a result of hazard assessment along yogurt production process, bacterial hazards were identified as significant hazards in pasteurization process, cooling at 45°C, packaging, storing and distribution. Also, Hazard assessment along cheese production process, bacterial hazards were identified as significant hazards in; pasteurization process, cooling at 45°C, put curd in molds, packaging, storing and distribution whilechemical contaminants during addition of salt (Nacl) and brine solution process was identified as significant hazards.
• Control measures that used for controlling biological hazards were supplier microbial analysis report, avoid cross contamination, and temperature control, while the control measures used for chemical hazards were approved supplier, who have chemical analysis reports for raw materials and the other control measure was using water from approved source. In addition, the control measure used for physical hazard was visual inspection.
• The categorization of yogurt shows that only temperature control for microbiological hazards in pasteurization process was managed as CCP. While, avoiding cross contamination by bacterial hazards in cooling process at 42°C, packaging, storage, and distribution were managed as OPRPs. On the other hand, the rest of control measures were categorized to be managed as PRPs.
• The categorization of cheese production presented that only temperature control for microbiological hazards in pasteurization process were managed as CCP. While, eight control measures were categorized as OPRPs which were; avoid bacterial cross contamination during cooling process 45°C (OPRP1), avoid bacterial cross contamination during putting curd in molds (OPRP2), Approved supplier to avoid chemical hazards during addition of Nacl (OPRP3), avoid cross contamination of biological hazard during addition of brine solution (OPRP4) and Approved supply of water to avoid chemical hazard (OPRP5), avoid cross contamination of biological hazards during packaging (OPRP 6), Temperature control to control bacterial proliferation (biological hazard during storage (OPRP 7) and distribution (OPRP 8).while the rest of control measures were categorized to be managed as PRPs.
• HACCP control plan for yogurt and cheese processing was established, including food safety hazards to be controlled at CCP ‘information for each control measure at each CCP; critical limits for each control measure at CCP; monitoring procedure(s); corrections made if critical limits not met; responsibilities and authorities; and records of monitoring.
• The critical limit for control CCP in yogurt (pasteurization process) was temperature control ≥85°C for 15 seconds, while in cheese ≥70°C for 15sec. while, several action criteria for control OPRPs in yogurt and cheese were established included; personal hygiene, cleaning and sterilizing equipment, temperature of storage and distribution vehicles less than 7°C.
• Several corrective actions were established for CCPs and OPRPs in dairy products production included stop process, avoid product release, test product, identify cause of nonconformity, or adjust pasteurization temperature.
• Monitoring procedures were conducted including planned observation or measurement identified by (who, what, when, and how).
• Established verification procedures to check if the HACCP plan was effective included; Accuracy of temperature recording devices, laboratory test, hand swabs, environmental swabs, review monitoring, corrective actions records…..etc
• All of these processes were documented according to ISO 22000:2018 system.
Phase III: Post-Implementation of FSMS ISO 22000:2018
• Dairy product plant appears to be completely complying with the requirement of FSMS ISO 22000:2018 in its 7th clauses as the overall score percentage of audited checklist was (100%).
• Physical, chemical properties and microbiological analysis results of water supply in dairy product plant showed positive indicator for the benefit of implementation of FSMS ISO 22000:2018, as total coliform count reduced to 1 colony\ml and absence of fecal coliform.
• Physical, chemical and microbiological analysis results indicated that the quality and safety of dairy products were enhanced positively after implementation of FSMS ISO 22000:2018.
• Regarding the microbial profile for yogurt, the mean value of mesophilic count (CFU/g), Total coliform (MPN/g), and E.coli (MPN/g) were decreased after ISO 22000:2018 Implementation, especially in end product where the mesophilic bacterial count decreased from (1.5x10 ⁴CFU\g to 1.1x10ᶾ CFU\g), and Total coliform (MPN/g), and E.coli (MPN/g) decreased from ( 6.2x10ᶾ and 2.2x10ᶾ respectively ) to <3 and 0.0.
• Regarding the microbial profile of cheese, the mean value of psychrotrophic count (CFU/g) and mesophilic count (CFU/g) were decreased after ISO 22000:2018 Implementation, especially in end product where psychrotrophic bacterial count decreased from (2.3x10² CFU\g to 2.7x10 CFU\g)), and Mesophilic bacterial count decreased from (2.0x10⁴ CFU\g to 2.5 x10ᶾ CFU\g).
• Regarding the microbiological examination of swab samples, the mean value of total viable count & staphylococcus aureus (CFU/g) were absent after implementation of ISO22000:2018 in the worker`s hands, equipment and utensils and packaging materials swabs. Meanwhile total coliform counts (MPN\g) were also decreased in equipment and utensils swabs and packaging materials swabs from (5.1x10 (MPN\g ) and 9 (MPN\g), respectively) to be absent.