Anda di halaman 1dari 47

Penn State Berkey Creamery Process Flow

Berkey Creamery
Process Flow Diagrams

Table of Contents:
Page 1 of 47

Penn State Berkey Creamery Process Flow


Raw Milk Receiving

pg.3

Whole Milk

pg.4

Skim Milk

pg.6

2% Milk

pg.8

Whole Chocolate Milk

pg.10

2% Chocolate Milk

pg.12

Cream

p.14

Cheddar Cheese

pg.16

Cream Cheese

pg.19

Light Cream Cheese

p.21

Flavored Cream Cheese

pg.23

Yogurt

p.25

Ricotta Cheese

pg.27

Sour Cream

pg.30

Flavored Sour Cream Dips

pg.32

Ice Cream

pg.35

Frozen Yogurt

pg.37

Sherbet

pg.39

Vanilla Soft Serve Frozen Yogurt

pg.41

Chocolate Soft Serve Frozen Yogurt

pg.43

Raw Milk Receiving

Page 2 of 47

Penn State Berkey Creamery Process Flow

Page 3 of 47

Penn State Berkey Creamery Process Flow

Whole Milk
Product Name
Plant Name
Ingredients
Packaging
Storage and Distribution

Intended Consumer
Shelf Life

Whole Milk
Penn State Berkey
Creamery
Milk, Vitamins A&D
16 oz, 32 oz, 64 oz, gallon
and 6 gal bag in box
Stored and distributed
under refrigeration below
40F
University dining halls, and
Creamery store
17 days from processing
date

Page 4 of 47

1.
2.
3.
4.
5.
6.
7.
8.

Raw Milk is received according to the Raw Milk Receiving Flowchart


Milk is pasteurized at 167F for 15-16 sec (high speed); exits HTST at 38-40F
Milk is homogenized at 2500psi
Pasteurized whole milk is held in PT#10 at 35-40F for no less than 30min under agitation
See Carton filling SOP (006.001)
See Bag Filling SOP (008.001)
Product is ink-jet printed with date of expiration (Code Date: 14 days from date of processing) and time of
packaging.
Packaged whole milk is held under refrigeration at 35-40F

* Duplicate samples taken for Standard Plate, Phosphatase, and Coliform Testing (in-house and outside labs)
** First and random carton samples taken for shelf life testing

Page 5 of 47

Skim Milk
Product Name
Plant Name
Ingredients
Packaging
Storage and Distribution

Intended Consumer
Shelf Life

Skim Milk
Berkey Creamery
Skim milk, vitamins A&D,
16 oz, 32 oz, 64 oz, gallon
and 6 gallon bag in box
Stored and distributed
under refrigeration below
40F
University dining halls,
Creamery Store
17 days from processing
date

Page 6 of 47

1.
2.
3.
4.
5.
6.
7.
8.
9.

Raw milk received according to Raw Milk Receiving Flow Chart


Raw milk is separated and cream is removed to be processed according to the Cream Flow Chart
Skim milk is pasteurized at 167F for 15-16 sec (high speed); exits HTST at 38-40F
Pasteurized skim milk is held in PT#7 at 35-40F for not less than 30 min under agitation.
Pasteurized skim milk is held in PT#7 at 35-40F for not less than 30 min under agitation.
See Carton filling SOP (006.001)
See Bag Filling SOP (008.001)
Product is ink-jet printed with date of expiration (Code Date: 14 days from date of processing) and time of
packaging.
Packaged skim milk is held under refrigeration at 35-40F

* Duplicate samples taken for Standard Plate, Phosphatase, and Coliform Testing (in-house and outside labs)
** First and random carton samples taken for shelf life testing

Page 7 of 47

2% Milk
Product Name
Plant Name
Ingredients
Packaging
Storage and Distribution

Intended Consumer
Shelf Life

2% Milk
Berkey Creamery
Skim milk, milk, Vitamins
A&D,
16 oz, 32 oz, 64 oz, gallon
and 6 gallon bag in box
Stored and distributed
under refrigeration below
40F
University dining halls,
Creamery Store
17 days from processing
date

Page 8 of 47

1.
2.
3.
4.
5.

Pasteurized whole milk and pasteurized skim milk are mixed for no less than 30 min under agitation in
PT#6 at 28F
See Carton filling SOP (006.001)
See Bag Filling SOP (008.001)
Product is ink-jet printed with date of expiration (Code Date: 14 days from date of processing) and
time of packaging.
Packaged 2% milk is held under refrigeration at 35-40F

* Duplicate samples taken for Standard Plate, Phosphatase, and Coliform Testing (in-house and outside labs)
** First and random carton samples taken for shelf life testing

Whole Chocolate Milk


Page 9 of 47

Product Name
Plant Name
Ingredients
Packaging
Storage and Distribution

Intended Consumer
Shelf Life

Whole Chocolate Milk


Berkey Creamery
Skim milk, milk, cocoa,
sugar, vitamins A&D
16 oz, 32 oz, 64 oz, gallon
Stored and distributed
under refrigeration below
40F
Creamery Store
17 days from processing
date

Page 10 of 47

1.
2.
3.
4.
5.
6.
7.
8.
9.

Raw milk is received according to the Raw Milk Receiving Flow Chart.
Raw milk is blended with dry ingredients in liquefier.
Raw chocolate milk is pumped into MT #11B and agitated
Chocolate whole milk is pasteurized at 180F for 15-16 sec (high speed): exits HTST at 38-40F
Chocolate whole milk is homogenized at 2500psi
Pasteurized chocolate whole milk is held in PT#7 (or PT#12) at 38F for no less than 30 min under
agitation.
See Carton filling SOP (006.001)
Product is ink-jet printed with date of expiration (Code Date: 14 days from the date of processing) and time
of packaging.
Packaged chocolate whole milk is held under refrigeration at 35-40F.

* Duplicate samples taken for Standard Plate, Phosphatase, and Coliform Testing (in-house and outside labs).
** First and random carton samples taken for shelf life testing.

Page 11 of 47

2% Chocolate Milk
Product Name
Plant Name
Ingredients
Packaging
Storage and Distribution

Intended Consumer
Shelf life

2% Chocolate Milk
Berkey Creamery
Skim milk, whole milk,
cocoa, sugar, vitamins A&D
6 gal bag-in-box containers
Stored and distributed
under refrigeration below
40F
University dining halls
17 days from processing
date

Page 12 of 47

1.
2.
3.
4.
5.
6.
7.
8.
9.

Raw milk is received according to the Raw Milk Receiving Flow Chart.
Raw milk is blended with dry ingredients in liquefier.
Raw chocolate milk pumped into MT #11B and agitated.
Chocolate whole milk is pasteurized at 180F for 15-16 sec (high speed); exits HTST at 38-40F.
Chocolate whole milk is homogenized at 2500psi.
Pasteurized chocolate whole milk is mixed with pasteurized skim milk in PT#7 (or PT#8) at 38F for no
less than 30min under agitation.
See bag filling SOP (008.001)
Product is ink-jet printed with date of expiration (Code date: 14 days from date of processing) and time
of packaging.
Packaged chocolate 2% milk is held under refrigeration at 35-40F.

* Duplicate samples taken for Standard Plate, Phosphatase, and Coliform testing (in-house and outside labs).

Page 13 of 47

Cream
Product Name
Plant Name
Ingredients
Packaging
Storage and distribution

Intended Consumer
Shelf life

Cream
Berkey Creamery
Cream
Packaged in 2.5 gallon and
6 gal bag-in-box containers
Stored and distributed
under refrigeration below
40F
University dining halls
21 days from processing
date

Page 14 of 47

1.
2.
3.
4.
5.
6.

Raw milk is received according to Raw Milk Receiving Flow Chart.


Raw milk is separated and skim milk is removed to be processed according to Skim Milk Flow Chart.
Cream is vat pasteurized in cream tank at 155-160F for no less than 30 min.
Cream is cooled in Cream Tank (Time Requirements)?
See bag filling SOP (008.001)
Product is ink-jet printed with date of expiration (code date: 21 days from date of processing) and time of
packaging.
7. Product is stored under refrigeration at 25-40F
* Duplicate samples taken for Standard Plate, Phosphatase, and Coliform Testing (in-house and outside labs)

Page 15 of 47

Cheddar Cheese
Product Name
Plant Name
Ingredients

Packaging

Storage and distribution


Intended consumer
Shelf Life

Cheddar Cheese
Penn State Berkey
Creamery
Milk, skim milk, color, salt,
rennet, starter, cultures,
water
Packaged in approx. 22lb
blocks, & 1lb vacuumsealed in poly bags
Stored and distributed
under refrigeration at 45F
University dining halls,
Creamery store
14 days after opening

Page 16 of 47

1. Raw milk is received according to Raw Milk Receiving Flow Chart.


2. Raw milk is pasteurized at 167F for 15-16 sec (high speed).
3.
a. Pasteurized cheddar milk is pumped directly to cheddar vat (cheese room) and heated while
coloring is added (.44mL/ gal milk); or
b. Pasteurized cheddar milk is pumped into PT#7 and held at 35-40F for no more than 72 hrs;
then pumped to cheddar vat and heated while coloring is added (.44mL/ gal milk).
4. When product reaches 72F, cultures are added (rotation of three types of cultures); product is agitated and
heated to 90F; stop agitation and allow to ripen (sit) for 1hr.
5. Single strength rennet (diluted with tap water) is added (.027oz/gal milk); product is agitated for 5 min. Turn
off agitator and allow product to sit for approx 30min (until sanitized finger comes out clean).
6. Product is cut into inch curds with stainless steel wire knives.

Page 17 of 47

7. Product is heated to 102F (1.5-2F/5min for a total of 30 min).See table.


8. Whey is drained; curds are piled on sides of vat.
9. Target TA=.22% acidityallow to sit until target TA is reached.
10.Cheddaring process (approx 1hr)
a. Product is cut into 10-12 inch slabs and flipped; run TA
b. After 10 min, slabs are flipped and stacked 3 high; run TA
c. After 10 min, slabs are flipped and stacked 4 high; run TA
d. Continue flipping and stacking slabs (4 high) until target TA is reached.
11.Target TA=.55% acidity.
12.Slabs are cut into 1 inch cubes.
13.Cubes are raked and salted (.4 oz-wt/gal milk) for approx 30 min.
14.Stainless steel Wilson hoops (lined with wet, disposable cheesecloth) are filled with salted cubes (approx
25lbs/hoop).
15.Hoops are stacked in hydraulic press (110psi) for 16-24hrs.
16.Cheddar is vacuum sealed in plastic bags.
17.Code date: packaged is hand stamped with packaging date.
18.Packaged cheddar is stored at 45F for no more than 6 months.
Cheddar Cooking Time-Temperature Table

Time
0min
10 min
20 min
30 min

Temperature
90F
93-94F
96-98F
99-102F

Cream Cheese
Product Name

Cream Cheese
Page 18 of 47

Plant Name
Ingredients

Packaging
Storage and distribution

Intended Consumer
Shelf Life

Penn State Berkey


Creamery
Milk, cream, skim milk
powder, stabilizer, salt,
rennet, starter cultures
8oz, 16oz, 5lb, 10lb tubs;
50lb bags
Stored and distributed
under refrigeration below
40F
University dining halls,
Creamery store
90 days from packaging
date

Page 19 of 47

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Raw milk is received according to the Raw Milk Receiving Flow Chart.
Raw milk is blended with dry ingredients in liquefier; cream is added under no agitation.
Cream cheese mix is pasteurized at 179-181F for 26 sec; exits HTST at 90-100F.
Mix is homogenized at 2500psi.
Mix is pumped to cone bottom processor under agitation, then cooled to 78-80F.
Starter cultures and rennet are added; agitate for 10min to mix; turn off agitator and lock out;
allow to sit (at 78-80F) for 20-24hrs.
Product is agitated for 5-10min.
Product is pumped into muslin bags and set in ricotta vat on a rack.
Bags are topped with 10gal cans (filled with water) and iced down for 40-48hrs.
Bags are emptied into kettand heated under agitation to approx 180F.
Product is homogenized at 2500psi.
Product is hand-filled by volume (8, 26, 40 oz tubs) and by weight (5, 10, 50lb bags).
Packaged cream cheese is hand-stamped with code date (3 months from packaging date) and
product name, weight.
Packaged cream cheese is cooled at room temperature for 3-6hrs.
Packaged product is stored under refrigeration at 35-40F.

Light Cream Cheese


Page 20 of 47

Product Name
Plant Name
Ingredients

Packaging used
Storage and distribution

Intended Consumer
Shelf Life

Light Cream Cheese


Penn State Berkey
Creamery
Milk, Cream, skim milk
powder, stabilizer, salt,
rennet, starter cultures
Packaged in 5, 10lb tubs,
50lb bags
Stored and distributed
under refrigeration below
40F
University dining halls,
Creamery Store
90 days from packaging
date

Page 21 of 47

1.
2.
3.
4.
5.
6.

Raw milk is received according to the Raw Milk Receiving Flow Chart.
Raw milk is blended with dry ingredients in liquefier; cream is added under no agitation.
Cream cheese mix is pasteurized at 179-181F for 26sec; exits HTST at 90-100F.
Mix is homogenized at 2500psi.
Mix is pumped into cone bottom processor under agitation, then cooled to 78-80F.
Starter cultures are rennet are added; agitate for 10min to mix; turn off agitator and lock out; allow to sit (at
78-80F) for 20-24hrs.
7. Product is agitated for 5-10min.
8. Product is pumped into muslin bags and set in ricotta vat on a rack.
9. Bags are topped with 10gal cans (filled with water) and iced down for 40-48hrs.
10.Bags are emptied into a kettle and heated under agitation to approximately 180F.
11.Product is homogenized at 2500psi.
12.Product is hand-filled by weight (5, 10lb tubs; 50lb bags).
13.Packaged cream cheese is hand-stamped with code date (3 months from packaging date) and product
name, weight.
14.Packaged cream cheese is cooled at room temperature for 3-6hrs.
15.Product is stored under refrigeration at 35-40F

Page 22 of 47

Flavored Cream Cheese


Product Name
Plant Name
Ingredients

Packaging
Storage and Distribution

Intended Consumer
Shelf Life

Flavored Cream Cheese


Penn State Berkey
Creamery
Milk, stabilizer, salt, rennet,
starter cultures, flavoring
ingredients
Packaged in 8oz and 5lb
containers
Stored and distributed
under refrigeration below
40F
University dining halls,
Creamery store
90 days from packaging
date

Page 23 of 47

1.
2.
3.
4.
5.

Cream cheese is processed according to Cream Cheese Flow Chart.


Finished cream cheese is melted under agitation to 160-170F in kettle.
Flavoring ingredients are added to cream cheese according to formulation, and blended thoroughly.
Flavored cream cheese is hand packaged while hot into 8oz and 5lb containers.
Flavored cream cheese is hand stamped with code date (3 months from original cream cheese packaging
date) and name of product.
6. Packaged flavored cream cheese is cooled at room temperature for 3-6hrs.
7. Cooled product is stored under refrigeration at 25-40F.

Page 24 of 47

Yogurt (plain and with fruit


ingredient)
Product
Plant
Ingredients
Packaging
Storage and Distribution

Intended Consumer
Shelf Life

Yogurt (plain and with fruit)


Penn State Berkey
Creamery
Skim milk, cream, skim milk
powder, sugar, stabilizer
Plain: 32oz and 8 oz; Fruit:
32 oz & 8oz cups
Stored and distributed
under refrigeration below
40F
University dining halls,
Creamery store
45 days from processing
date

Page 25 of 47

1. Dry ingredients are blended in liquefier with pasteurized skim milk; cream is added without agitation
(Target=2% MF, 12% MSNF).
2. Yogurt mix is sent to MT#11 (A or B)
3. Mix is pasteurized at 180F for 25s; exits HTST at 130-140F.

Page 26 of 47

4. Mix is homogenized at 2500psi.


5. Pasteurized, homogenized mix is pumped to cone-bottom processor; agitator on low speed.
6. Depending on processing schedule, product may be cooled to 32-38F.
7. When processing yogurt, mix is repasteurized at 187F.
8. Mix is cooled (with cooling jacket) to 108-110F.
9. Starter cultures are added to mix; mix is agitated for 10 min.
10.Agitator is shut off and locked out, and mix is allowed to ferment for 3-5 hrs.
11.After 3 hrs, bacterial growth is monitored with TA test until target acidity (TA =.9%) is reached.
12.Product is cooled (cooling jacket) under low speed agitation until temperature is below 70F. When target
temperature is reached, agitation is turned off.
13.Product is pumped to cup filling machine, where 2oz fruit is added to bottom of cup, follow by 6oz yogurt
(total wt=227g). Cup is then heat sealed with plastic and lidded.
14.Code date: 42-45 days from packaging date.
15.Product is stored at 35-40F.

Ricotta Cheese
Product Name
Plant
Ingredients

Packaging
Storage and Distribution

Intended Consumer
Shelf Life

Ricotta Cheese
Penn State Berkey
Creamery
Milk, skim milk powder,
white vinegar, salt,
potassium sorbate, citric
acid
Packaged in 10lb containers
Stored and distributed
under refrigeration below
40F
University dining halls
45 days from processing
date

Page 27 of 47

Page 28 of 47

1.
2.
3.
4.
5.
6.
7.
8.

Raw milk is received according to the Raw Milk Receiving Flow Chart.
Raw milk is heated slightly and agitated in liquefier to dissolve solid ingredients;
Raw milk is pumped to MT #11 (A or B)
Ricotta milk is pasteurized at 179-181F for 26 sec (low speed).
Ricotta milk is pumped to ricotta vat.
White vinegar is added under agitation (low speed) to lower pH and precipitate curd.
Target pH=6.0; add vinegar as needed.
Potassium sorbate and salt are mixed together and added to milk; product is heated to 178F under
agitation (low speed).
9. Product rests, undisturbed for 30 min.
10.Citric acid is added under agitation (low speed) to lower pH and precipitate curd.
11.Agitate 5-6min to evenly blend.
12.Agitate for 5-6min to evenly blend.
13.Turn off agitator, let curds settle for 5-10 min.
14.Turn on cooling jacket; allow to cool for 5-10 min.
15.Drain of whey into perforated basket; press excess whey out of curds with plastic spatulas; return drained
curds to vat.
16.Hand-fill by weight into 10lb tubs.
17.Hand stamp code date (45 days from processing), product name and weight.
18.Store packaged ricotta cheese at 35-40F.

Page 29 of 47

Sour Cream

Page 30 of 47

Product Name
Plant
Ingredients

Packing
Storage and Distribution

Intended Consumer
Shelf Life

Sour Cream
Penn State Berkey
Creamery
Milk, skim milk powder,
cream, stabilizer,
buttermilk, rennet
Packaged in pint, quart and
5qt containers
Stored and distributed
under refrigeration below
40F
University dining halls,
Creamery Store
45 days from packaging
date

Page 31 of 47

1. Raw milk is received according to Raw Milk Receiving Flow Chart.


2. Raw milk is blended with dry ingredients in liquefier; cream is added under no agitation.
3. Raw milk is pumped to MT#11 (A or B) and agitated to thoroughly blend.
4. Sour cream mix is pasteurized at 179-181F for 26sec; exits HTST at 78-90F.
5. Mix is homogenized at 2500psi.
6. Mix is pumped to sour cream vat.
7. Buttermilk and rennet are added and mix is agitated.
8. Sour cream mix is hot packed into pint, quart and 5qt containers.
9. Product sets, undisturbed, for 24 hours.
10.Product is stamped with code date, product name and weight; code date is 45 days from packaging date.
11.Packaged product is stored under refrigeration at 35-40F.

Flavored sour cream dips


Page 32 of 47

Product Name
Plant
Ingredients

Packaging
Storage and Distribution

Intended Consumer
Shelf Life

Flavored sour cream dips


Penn State Berkey
Creamery
Pasteurized milk, skim milk
solids, stabilizer, buttermilk,
rennet, flavoring
8oz and 5lb containers
Stored and distributed
under refrigeration below
40F
University dining halls,
Creamery
45 days from date of
packaging

Page 33 of 47

1.
2.
3.
4.
5.
6.
7.
8.
9.

Raw milk is received according to Raw Milk Receiving Flow Chart.


Raw milk is blended with dry ingredients in liquefier; cream is added under no agitation.
Raw milk is pumped to MT#11 (A or B) and agitated to thoroughly blend.
Sour cream mix is pasteurized at 179-181F for 26sce; exits HTST at 78-90F.
Mix is homogenized at 2500psi.
Mix is pumped to sour cream vat.
Buttermilk and rennet are added and mix is agitated.
Sour cream mix is hot packed into 8oz and 5lb containers.
Product sets, undisturbed for 24 hrs.

Page 34 of 47

10.Sour cream is placed in plastic tub; flavoring ingredients are added according to formulation and blended
thoroughly.
11.Flavored sour cream dip is repackaged.
12.Finished product is hand stamped with code date (45 days from processing date) and flavor name.
13.Finished product is stored under refrigeration at 35-40F.

Page 35 of 47

Ice Cream
Product Name
Plant Name
Ingredients

Packaging

Storage and Distribution

Intended Consumer
Shelf life

Ice Cream
Penn State Berkey
Creamery
Pasteurized milk, skim milk
powder, sugar, dry corn
syrup solids, stabilizer,
liquid and solid flavoring
3gal cartons, 1/2gal
cartons, pints, and 4oz
Dixie cups
Stored and distributed
under refrigeration below (25F)
University dining halls,
Creamery store
150 days from freezing date

Page 36 of 47

1.
2.
3.
4.
5.
6.
7.
8.

Raw milk is received according to the Raw milk Receiving Flow Chart.
Dry ingredients are blended with raw milk in liquefier; pasteurized cream is added under no agitation.
Raw mix is pumped to MT#11 (A or B) and thoroughly mixed.
Mix is pasteurized at 179-181F for 15-16 sec (low speed); exits SHTST at 45-52F.
Mix is homogenized at 2500psi.
Pasteurized mix is aged at 30-35F for 24hrs in Ice Cream Tank#2.
Liquid ingredients (i.e .flavoring, coloring) are added.
Freezing: 80% overrun, 21-29F.

Page 37 of 47

9. Insufficiently frozen mix is collected and returned to flavor vats for reworking.
10.Solid ingredients (i.e. chips, fruit, nuts) are added.
11.Variegate (i.e. fudge ripple, peanut butter swirl) is added.
12.Frozen, flavored mix is sent to filling machines.
13.Code date: 150 days from freezing date, 3gal bulk containers are hand stamped with code date and product
name; gallons, pints and dixies are dated by ink-jet.
14.Hardening: (-20 to -25)F for 12-14hours.
* Sample taken for Standard Plate, Coliform, and Yeast and Mold Tests (monthly phosphatase test on ice cream mix).

Page 38 of 47

Frozen Yogurt
Product Name
Plant Name
Ingredients

Packaging
Storage and Distribution

Intended Consumer
Shelf Life

Frozen Yogurt
Penn State Berkey
Creamery
Milk, skim milk powder,
sugar, dry corn syrup solids,
stabilizer, yogurt, liquid
flavoring ingredients
Packaged in gal cartons
and 3 gal bulk cartons
Stored and distributed
under refrigeration below (25F)
University Dining halls,
Creamery Store
180 days from freezing date

Page 39 of 47

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Raw milk is received according to Raw Milk Receiving Flow Chart.


Dry ingredients are blended with raw milk in liquefier; cream is added without agitation.
Raw milk is pumped to MT#11 (A or B) to thoroughly blend (Temp?)
Mix is pasteurized at 179-181F for 15-16 sec (low speed); exits HTST at 45-52F.
Mix is homogenized at 2500psi.
Pasteurized mix is aged at 30-35F for 24hrs; pasteurized yogurt is added.
Liquid ingredients (i.e. flavoring, coloring) are added.
Freezing (80% overrun, 21-29F.
Insufficiently frozen mix is collected and returned to flavor vats for reworking.
Solid ingredients (i.e. fruit) are added.
Frozen, flavored mix is sent to filling machines.
Code date: 180 days from freezing date- bulk containers are hand stamped with date and product name;
gallons are ink-jet dated.
13. Hardening (-20 to -25F). for 12-14 hours.

Page 40 of 47

* Sample taken for Coliform , and yeast and Mold Tests (monthly phosphatase test on frozen yogurt mix).

Sherbet
Product
Plant
Ingredients

Packaging
Storage and Distribution

Intended Consumer
Shelf Life

Sherbet
Penn State Berkey
Creamery
Lowfat milk, skim milk,
water, cream, sugar, dry
corn syrup solids, stabilizer,
liquid flavoring
Packaged in quarts and 3gal
bulk containers
Stored and distributed
under refrigeration below (25F)
Penn State Berkey
Creamery
150 days from freezing date

Page 41 of 47

1. Dry ingredients are blended with pasteurized skim milk, lowfat milk, and water in liquefier; cream is added
under no agitation.
2. Sherbet mix is pumped to MT#11 (A or B) to thoroughly blend.
3. Mix is pasteurized at 179-181F for 15-16sec (low speed); exits HTST at 45-52F.
4. Mix is homogenized at 2500psi.
5. Pasteurized mix is aged at 30-35F for 24hrs; pasteurized yogurt is added.

Page 42 of 47

6. Liquid ingredients (i.e. flavoring, coloring) are added.


7. Freezing: 80% overrun 21-29 F.
8. Insufficiently frozen mix is collected and returned to flavoring vats for reworking.
9. Frozen, flavored sherbet is sent to bulk filling machine; quarts are hand filled from bulk filling machine.
10.Code date: 180 days from freezing datequart and bulk containers are hand stamped with date and
product name.
11.Hardening (-20 to -25F) for 12-24 hours.
* Sample taken for standard Plate, Coliform, and Yeast and Mold Tests (monthly phosphatase test on sherbet mix).

Vanilla Soft Serve Frozen Yogurt


Product
Plant
Ingredients
Packaging
Storage and Distribution

Intended Consumer
Shelf Life

Vanilla Soft Serve Frozen


Yogurt
Penn State Berkey
Creamery
Milk, skim milk powder,
sugar, stabilizer, yogurt
Packaged in 2.5 gallon bagin-box containers
Stored and distributed
under refrigeration below
40F
University dining halls
30 days from processing
date

Page 43 of 47

1.
2.
3.
4.
5.
6.
7.
8.
9.

Raw milk is received according to Raw Milk Receiving Flow Chart.


Dry ingredients are blended with raw milk in liquefier; pasteurized cream is added under no agitation.
Raw milk is pumped to MT #11 (A or B) to thoroughly blend.
Mix is pasteurized at 179-181F for 15-16 sec (low speed); exits HTST at 45-52F.
Mix homogenized at 2500psi.
Pasteurized mix is cooled in PT#10 or cream Vat to 30-35F.
Pasteurized mix is sent to bag in box filler.
Product is tagged with product name and code date (30 days from processing date).
Packaged product is stored at 35-40F.

* Sample taken for Coliform, and Yeast and Mold Tests (and monthly phosphatase test).

Page 44 of 47

Chocolate Soft Serve Frozen


Yogurt
Product
Plant
Ingredients

Packaging
Storage and Distribution

Intended Consumer
Shelf Life

Chocolate Soft Serve Frozen


Yogurt
Penn State Berkey
Creamery
Milk, skim milk powder,
cocoa, sugar, stabilizer,
yogurt
2.5 gallon bag-in-box
containers
Stored and distributed
under refrigeration below
40F
University dining halls
30 days from processing
date

Page 45 of 47

Page 46 of 47

1.
2.
3.
4.
5.
6.
7.
8.
9.

Raw milk is received according to Raw Milk Receiving Flow Chart.


Dry ingredients are blended with raw milk in liquefier; pasteurized cream is added under no agitation.
Raw milk is pumped to MT #11 (A or B) to thoroughly blend.
Mix is pasteurized at 179-181F for 15-16 sec (low speed); exits HTST at 45-52F.
Mix is homogenized at 2500psi.
Pasteurized mix is cooled in PT#10 or Cream Vat to 30-35F.
Pasteurized mix is sent to bag-in-box filler.
Product is tagged with product name and code date (30 days from processing date).
Product is stored at 35-40F.

* Sample taken for Coliform, and Yeast and Mold Tests (and monthly phosphatase test).

Page 47 of 47