Process Flow Diagrams

Penn State Berkey Creamery Process Flow 2014

Berkey Creamery

Process Flow Diagrams

Page 1 of 45


Table of Contents: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

Page 2 of 45


Raw Milk Receiving

Raw MilkReceiving

Tanker EntersReceiving Bay

Driver EngagesRaw Silo

Refrigeration

Driver OpensTank Cover

Driver Pumps MilkTo Raw Silo

Driver Rinses Receiving Lines

AB, TempTesting

Reject RawMilkNO

Accept RawMilk

YES

Page 3 of 45


Whole Milk

Product Name Whole MilkPlant Name Penn State Berkey CreameryIngredients Milk, Vitamins A&DPackaging 16 oz, 32 oz, 64 oz, gallon and 6 gal

bag in boxStorage and Distribution Stored and distributed under

refrigeration below 40°FIntended Consumer University dining halls, and

Creamery storeShelf Life 17 days from processing date

Page 4 of 45


Whole MilkProduction

Raw MilkReceiving

(1)

VitaminsA&D

Pasteurizing(3)

Holding(5)

Homogenizing(4)

Carton Filling(5)**

Bag Filling(6)

6galBags

Code Dating(7)

QtCartons

1/3 qt Cartons

½ gal Cartons

RefrigeratedStorage

(8)

1. Raw Milk is received according to the Raw Milk Receiving Flowchart2. Milk is pasteurized at 167°F for 15-16 sec (high speed); exits HTST at 38-40°F3. Milk is homogenized at 2500psi4. Pasteurized whole milk is held in PT#10 at 35-40°F for no less than 30min under agitation5. See Carton filling SOP (006.001)6. See Bag Filling SOP (008.001)7. Product is ink-jet printed with date of expiration (Code Date: 14 days from date of processing) and time of packaging.8. Packaged whole milk is held under refrigeration at 35-40°F

* 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 45


Skim Milk

Product Name Skim MilkPlant Name Berkey CreameryIngredients Skim milk, vitamins A&D,Packaging 16 oz, 32 oz, 64 oz, gallon and 6

gallon bag in boxStorage and Distribution Stored and distributed under

refrigeration below 40°FIntended Consumer University dining halls, Creamery

StoreShelf Life 17 days from processing date

Page 6 of 45



Raw MilkReceiving

(1)

Cream To: CreamProcess

Separating(2)

Skim Milk

VitaminsA&D

Defoamer

Pasteurizing(3)

Holding(5)

Homogenizing(4)

Carton Filling(5)**

Bag Filling(6)

6galBags

Code Dating(7)

QtCartons

1/3 qt Cartons

½ gal Cartons

RefrigeratedStorage

(8)

1. Raw milk received according to Raw Milk Receiving Flow Chart2. Raw milk is separated and cream is removed to be processed according to the Cream Flow Chart3. Skim milk is pasteurized at 167°F for 15-16 sec (high speed); exits HTST at 38-40°F4. Pasteurized skim milk is held in PT#7 at 35-40°F for not less than 30 min under agitation.5. Pasteurized skim milk is held in PT#7 at 35-40°F for not less than 30 min under agitation.6. See Carton filling SOP (006.001)7. See Bag Filling SOP (008.001)8. Product is ink-jet printed with date of expiration (Code Date: 14 days from date of processing) and time of packaging.9. Packaged skim milk is held under refrigeration at 35-40°F



Page 7 of 45


2% Milk

Product Name 2% MilkPlant Name Berkey CreameryIngredients Skim milk, milk, Vitamins A&D,Packaging 16 oz, 32 oz, 64 oz, gallon and 6

gallon bag in boxStorage and Distribution Stored and distributed under

refrigeration below 40°FIntended Consumer University dining halls,

Creamery StoreShelf Life 17 days from processing date

Page 8 of 45



Mixing(1)*

Carton Filling(2)**

Bag Filling(3)

6galBags

Code Dating(4)

QtCartons

1/3 qt Cartons

½ gal Cartons

RefrigeratedStorage

(5)

Pasteurized Skim Milk

PasteurizedWhole Milk

1. Pasteurized whole milk and pasteurized skim milk are mixed for no less than 30 min under agitation in PT#6 at 28°F2. See Carton filling SOP (006.001)3. See Bag Filling SOP (008.001)4. Product is ink-jet printed with date of expiration (Code Date: 14 days from date of processing) and time of packaging.5. Packaged 2% milk is held under refrigeration at 35-40°F



Page 9 of 45


Whole Chocolate Milk

Product Name Whole Chocolate MilkPlant Name Berkey CreameryIngredients Skim milk, milk, cocoa, sugar,

vitamins A&DPackaging 16 oz, 32 oz, 64 oz, gallon

Storage and Distribution Stored and distributed under refrigeration below 40°F

Intended Consumer Creamery StoreShelf Life 17 days from processing date

Page 10 of 45


Whole ChocolateMilk

Raw MilkReceiving

(1)

Blending(2)SugarCocoa

Batching(3)

Vitamins A&D

Pasteurizing(4)

Homogenizing(5)

Holding(6)

Carton Filling(7)**

QtCartons

1/3 QtCartons

Code Dating(8)

RefrigeratedStorage

(9)

1. Raw milk is received according to the Raw Milk Receiving Flow Chart.2. Raw milk is blended with dry ingredients in liquefier. 3. Raw chocolate milk is pumped into MT #11B and agitated4. Chocolate whole milk is pasteurized at 180°F for 15-16 sec (high speed): exits HTST at 38-40°F 5. Chocolate whole milk is homogenized at 2500psi6. Pasteurized chocolate whole milk is held in PT#7 (or PT#12) at 38°F for no less than 30 min under agitation.7. See Carton filling SOP (006.001)8. Product is ink-jet printed with date of expiration (Code Date: 14 days from the date of processing) and time of packaging.9. Packaged chocolate whole milk is held under refrigeration at 35-40°F.

* 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 45


2% Chocolate Milk

Product Name 2% Chocolate MilkPlant Name Berkey CreameryIngredients Skim milk, whole milk, cocoa,

sugar, vitamins A&DPackaging 6 gal bag-in-box containers


Intended Consumer University dining hallsShelf life 17 days from processing date

Page 12 of 45


2% Chocolate Milk

Raw MilkReceiving

(1)

Blending(2)SugarCocoa

Batching(3)

VitaminsA&D

Pasteurizing(4)

Homogenizing(5)

Holding(6)

PasteurizedSkim Milk

Bag Filling(7)

6 GalBags

Code Dating(8)

RefrigeratedStorage

(9)

1. Raw milk is received according to the Raw Milk Receiving Flow Chart.2. Raw milk is blended with dry ingredients in liquefier.3. Raw chocolate milk pumped into MT #11B and agitated.4. Chocolate whole milk is pasteurized at 180°F for 15-16 sec (high speed); exits HTST at 38-40°F.5. Chocolate whole milk is homogenized at 2500psi.6. Pasteurized chocolate whole milk is mixed with pasteurized skim milk in PT#7 (or PT#8) at 38°F for no less than 30min under

agitation.7. See bag filling SOP (008.001)8. Product is ink-jet printed with date of expiration (Code date: 14 days from date of processing) and time of packaging.9. Packaged chocolate 2% milk is held under refrigeration at 35-40°F.

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

Page 13 of 45


Cream

Product Name CreamPlant Name Berkey CreameryIngredients CreamPackaging Packaged in 2.5 gallon and 6 gal

bag-in-box containersStorage and distribution Stored and distributed under

refrigeration below 40°FIntended Consumer University dining halls

Shelf life 21 days from processing date

Page 14 of 45


Cream

Raw Milk Receiving

(1)

Separating(2) Skim milk To Skim milk

Production

Cream

VatPasteurizing

(3)

Cooling(4)*

Bag Filling(5)

6 galBag-in-box

Code dating(6)

RefrigeratedStorage

(7)

1. Raw milk is received according to Raw Milk Receiving Flow Chart.2. Raw milk is separated and skim milk is removed to be processed according to Skim Milk Flow Chart.3. Cream is vat pasteurized in cream tank at 155-160°F for no less than 30 min.4. Cream is cooled in Cream Tank (Time Requirements)?5. See bag filling SOP (008.001)6. 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 25-40°F


Page 15 of 45


Cheddar Cheese

Product Name Cheddar CheesePlant Name Penn State Berkey CreameryIngredients Milk, skim milk, color, salt, rennet,

starter, cultures, waterPackaging Packaged in approx. 22lb blocks, &

1lb vacuum-sealed in poly bagsStorage and distribution Stored and distributed under

refrigeration at 45°FIntended consumer University dining halls, Creamery

storeShelf Life 14 days after opening

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Skim milk Pasteurizing(2)

Raw Milk Receiving

CheddarCheese

Pumping to Vat(3a)Coloring

Pumping to Storage tank

(3b)

Ripening(4)

StarterCultures

Setting(5)Rennet

Cutting(6)

Cooking (7)

Draining(8)

TA Test(9)

Cheddaring

YES

NO

Whey Removal

WheyDisposal

TATest(11)

NO

Milling (12)

YES

Salting(13)Salt

Hooping(14)

Cheese-cloth

Pressing(15)

Packaging(16)

Code Dating(17)

Aging(18)

Ready forSale

1. Raw milk is received according to Raw Milk Receiving Flow Chart.2. Raw milk is pasteurized at 167°F 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 35-40°F for no more than 72 hrs; then pumped to cheddar vat and heated while coloring is added (.44mL/ gal milk).

4. When product reaches 72°F, cultures are added (rotation of three types of cultures); product is agitated and heated to 90°F; 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 ¼ inch curds with stainless steel wire knives.7. Product is heated to 102°F (1.5-2°F/5min for a total of 30 min).—See table.

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8. Whey is ¾ drained; curds are piled on sides of vat.9. Target TA=.22% acidity—allow to sit until target TA is reached.10. Cheddaring process (approx 1hr)

a. Product is cut into 10-12 inch slabs and flipped; run TAb. After 10 min, slabs are flipped and stacked 3 high; run TAc. After 10 min, slabs are flipped and stacked 4 high; run TAd. 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 45°F for no more than 6 months.

Cheddar Cooking Time-Temperature Table

Time Temperature0min 90°F

10 min 93-94°F20 min 96-98°F30 min 99-102°F

Page 18 of 45


Cream Cheese

Product Name Cream CheesePlant Name Penn State Berkey CreameryIngredients Milk, cream, skim milk powder,

stabilizer, salt, rennet, starter cultures

Packaging 8oz, 16oz, 5lb, 10lb tubs; 50lb bags

Storage and distribution Stored and distributed under refrigeration below 40°F

Intended Consumer University dining halls, Creamery store

Shelf Life 90 days from packaging date

Page 19 of 45


Cream CheeseProduction

Raw MilkReceiving

(1)

Blending(2)

Skim Milk Powder

PasteurizedCream

Batching(3)

Pasteurizing(4)

Homogenizing(5)

StarterCultures

Fermentation(6)Rennet

Breaking(7)

Bag Filling(8)

Draining(9)

Whey Removal Whey Disposal

Cooking(10)

Homogenizing(11)

Salt

Stabilizer

Hot Packing(12)

5, 10, 50lbbags

Code Dating(13)

8, 16, 40 oz tubs

Room TempCooling

(14)

RefrigeratedStorage

(15)

1. Raw milk is received according to the Raw Milk Receiving Flow Chart.2. Raw milk is blended with dry ingredients in liquefier; cream is added under no agitation.3. Cream cheese mix is pasteurized at 179-181°F for 26 sec; exits HTST at 90-100°F.4. Mix is homogenized at 2500psi.5. Mix is pumped to cone bottom processor under agitation, then cooled to 78-80°F.6. Starter cultures and rennet are added; agitate for 10min to mix; turn off agitator and lock out; allow to sit (at 78-80°F) 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 kettand heated under agitation to approx 180°F.11. Product is homogenized at 2500psi.12. Product is hand-filled by volume (8, 26, 40 oz tubs) and by weight (5, 10, 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. Packaged product is stored under refrigeration at 35-40°F.

Page 20 of 45


Light Cream Cheese

Product Name Light Cream CheesePlant Name Penn State Berkey CreameryIngredients Milk, Cream, skim milk powder,

stabilizer, salt, rennet, starter cultures

Packaging used Packaged in 5, 10lb tubs, 50lb bagsStorage and distribution Stored and distributed under

refrigeration below 40°FIntended Consumer University dining halls, Creamery

StoreShelf Life 90 days from packaging date

Page 21 of 45


Light Cream Cheese

Production

Raw MilkReceiving

(1)

Blending(2)

Skim Milk Powder

PasteurizedCream

Batching(3)

Pasteurizing(4)

Homogenizing(5)

StarterCultures

Fermentation(6)Rennet

Breaking(7)

Bag Filling(8)

Draining(9)

Whey Removal Whey Disposal

Cooking(10)

Homogenizing(11)

Salt

Stabilizer

Hot Packing(12)5, 10lb tubs

Code Dating(13)

Room TempCooling

(14)

RefrigeratedStorage

(15)

50lb bags

1. Raw milk is received according to the Raw Milk Receiving Flow Chart. 2. Raw milk is blended with dry ingredients in liquefier; cream is added under no agitation.3. Cream cheese mix is pasteurized at 179-181°F for 26sec; exits HTST at 90-100°F.4. Mix is homogenized at 2500psi.5. Mix is pumped into cone bottom processor under agitation, then cooled to 78-80°F.6. Starter cultures are rennet are added; agitate for 10min to mix; turn off agitator and lock out; allow to sit (at 78-80°F) 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 180°F.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 35-40°F

Page 22 of 45


Flavored Cream Cheese

Product Name Flavored Cream CheesePlant Name Penn State Berkey CreameryIngredients Milk, stabilizer, salt, rennet, starter

cultures, flavoring ingredientsPackaging Packaged in 8oz and 5lb containers




Page 23 of 45


Flavored Cream Cheese

Production

Cream Cheese

Production(1)

Melting(2)

Blending(3)

FlavoringIngredients

Hot Packing(4)

8ozContainers

Code Dating(5)

5lb Containers

Room TempCooling

96)

RefrigeratedStorage

(7)

1. Cream cheese is processed according to Cream Cheese Flow Chart.2. Finished cream cheese is melted under agitation to 160-170°F in kettle.3. Flavoring ingredients are added to cream cheese according to formulation, and blended thoroughly.4. Flavored cream cheese is hand packaged while hot into 8oz and 5lb containers. 5. 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 25-40°F.

Page 24 of 45


Yogurt (plain and with fruit ingredient)

Product Yogurt (plain and with fruit)Plant Penn State Berkey Creamery

Ingredients Skim milk, cream, skim milk powder, sugar, stabilizer

Packaging Plain: 32oz and 8 oz; Fruit: 32 oz & 8oz cups



Shelf Life 45 days from processing date

Page 25 of 45


YogurtProduction

Blending(1)

Sugar

Skim MilkPowder

Stabilizer

Pasteurized Skim Milk

Pasteurized Cream

Batching(2)

Pasteurizing(3)

Pumping(5)

Homogenizing(4)

Vat Pasteurizing(7)

Cooling(6)

Cooling(8)

Agitating(9)

Starter Cultures

Fermentation(10)

TATest(11)

NO

Breaking(12)

YES

Filling(13)

Code Dating(14)

RefrigeratedStorage

(15)

8oz Cups

FruitFilling

32oz Cups

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 180°F for 25s; exits HTST at 130-140°F.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 32-38°F.7. When processing yogurt, mix is repasteurized at 187°F.8. Mix is cooled (with cooling jacket) to 108-110°F.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 70°F. 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 35-40°F.

Page 26 of 45


Ricotta Cheese

Product Name Ricotta CheesePlant Penn State Berkey Creamery

Ingredients Milk, skim milk powder, white vinegar, salt, potassium sorbate,

citric acidPackaging Packaged in 10lb containers


Intended Consumer University dining hallsShelf Life 45 days from processing date

Page 27 of 45


Ricotta CheeseProduction

Raw MilkReceiving

(1)

Blending(2)

Batching(3)

Skim Milk Powder

Cream

Pasteurizing(4)

Pumping to Ricotta Vat

(5)

1st Precipitation(6)Vinegar

pH Test(7)NO

Cooking(8)

YES

PotassiumSorbate

Resting(9)Salt

2nd Precipitation(10)Citric Acid

pH Test(11)NO

Agitating(12)

YES

Resting(13)

Cooling(14)

Draining(15)

Filling(16)

Code Dating(17)

Refrigerated Storage

(18)

Whey Removal

WheyDisposal

10lbTubs

1. Raw milk is received according to the Raw Milk Receiving Flow Chart.2. Raw milk is heated slightly and agitated in liquefier to dissolve solid ingredients;3. Raw milk is pumped to MT #11 (A or B)4. Ricotta milk is pasteurized at 179-181°F for 26 sec (low speed).5. Ricotta milk is pumped to ricotta vat.6. White vinegar is added under agitation (low speed) to lower pH and precipitate curd.7. Target pH=6.0; add vinegar as needed.8. Potassium sorbate and salt are mixed together and added to milk; product is heated to 178°F 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.

Page 28 of 45


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 35-40°F.

Page 29 of 45


Sour Cream

Product Name Sour CreamPlant Penn State Berkey Creamery

Ingredients Milk, skim milk powder, cream, stabilizer, buttermilk, rennet

Packing Packaged in pint, quart and 5qt containers


Intended Consumer University dining halls, Creamery Store


Page 30 of 45


Sour CreamProduction

Raw MilkReceiving

(1)

Blending(2)

Batching(3)

Pasteurizing(4)

Pumping(6)

Agitating(7)

Packaging(8)

Setting(9)

Code Dating(10)

RefrigeratedStorage

(11)

Stabilizer

Skim MilkPowder

Cream

Homogenizing(5)

Rennet

Buttermilk

Pintcontainer

5 qt container

1qt container

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 179-181°F for 26sec; exits HTST at 78-90°F.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 35-40°F.

Page 31 of 45


Flavored sour cream dips

Product Name Flavored sour cream dipsPlant Penn State Berkey Creamery

Ingredients Pasteurized milk, skim milk solids, stabilizer, buttermilk, rennet,

flavoringPackaging 8oz and 5lb containers


Intended Consumer University dining halls, CreameryShelf Life 45 days from date of packaging

Page 32 of 45


Sour CreamProduction

Raw MilkReceiving

(1)

Blending(2)

Batching(3)

Pasteurizing(4)

Pumping(6)

Agitating(7)

Packaging(8)

Blending(10)

Code Dating(12)

RefrigeratedStorage

(11)

Stabilizer

Skim MilkPowder

Cream

Homogenizing(5)

Rennet

Buttermilk

5lbcontainer

Setting (9)

Repackaging(11)

Flavoringingredients

8oz containers

5lbcontainers

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 179-181°F for 26sce; exits HTST at 78-90°F.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 8oz and 5lb containers.9. Product sets, undisturbed for 24 hrs. 10. Sour cream is placed in plastic tub; flavoring ingredients are added according to formulation and blended thoroughly.

Page 33 of 45


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 35-40°F.

Page 34 of 45


Ice Cream

Product Name Ice CreamPlant Name Penn State Berkey CreameryIngredients Pasteurized milk, skim milk

powder, sugar, dry corn syrup solids, stabilizer, liquid and solid

flavoringPackaging 3gal cartons, 1/2gal cartons, pints,

and 4oz Dixie cupsStorage and Distribution Stored and distributed under

refrigeration below (-25°F)Intended Consumer University dining halls, Creamery

storeShelf life 150 days from freezing date

Page 35 of 45


Ice CreamProduction

Raw MilkReceiving

(1)Stabilizer

Skim MilkPowder

Sugar Blending(2)

Dry CornSyrupSolids

Cream

Batching(3)

Pasteurizing(4)

Homogenizing(5)

Aging(6)*

Liquid Flavoring(7)

Freezing(8)

Solid Flavoring(10)

Variegating(11)

LiquidIngredients

Air

SolidIngredients

Rework(9)

Variegate

4ozDixies

Pints

½gal Cartons

Filling(12)

3galBulk

Code Dating(13)

Hardening(14)

*

Storage andDistribution

SufficientlyMixed?

YES

NO

1. Raw milk is received according to the Raw milk Receiving Flow Chart.2. Dry ingredients are blended with raw milk in liquefier; pasteurized cream is added under no agitation.3. Raw mix is pumped to MT#11 (A or B) and thoroughly mixed.4. Mix is pasteurized at 179-181°F for 15-16 sec (low speed); exits SHTST at 45-52°F.5. Mix is homogenized at 2500psi.6. Pasteurized mix is aged at 30-35°F for 24hrs in Ice Cream Tank#2.7. Liquid ingredients (i.e .flavoring, coloring) are added.8. Freezing: 80% overrun, 21-29°F. 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.

Page 36 of 45


13. Code date: 150 days from freezing date, 3gal bulk containers are hand stamped with code date and product name; ½ 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 37 of 45


Frozen Yogurt

Product Name Frozen YogurtPlant Name Penn State Berkey CreameryIngredients Milk, skim milk powder, sugar, dry

corn syrup solids, stabilizer, yogurt, liquid flavoring ingredients

Packaging Packaged in ½ gal cartons and 3 gal bulk cartons

Storage and Distribution Stored and distributed under refrigeration below (-25°F)

Intended Consumer University Dining halls, Creamery Store

Shelf Life 180 days from freezing date

Page 38 of 45


Ice CreamProduction

Raw MilkReceiving

(1)Stabilizer

Skim MilkPowder

Sugar Blending(2)

Dry CornSyrupSolids

Cream

Batching(3)

Pasteurizing(4)

Homogenizing(5)

Aging(6)*

Liquid Flavoring(7)

Freezing(8)

Solid Flavoring(10)

LiquidIngredients

Air

Rework(9)

Solid ingredients

½ gal cartons

3 gal bulk

Filling(11)

Code Dating(12)

Hardening(13)

*


NOSufficiently Mixed:?

YES

1. Raw milk is received according to Raw Milk Receiving Flow Chart.2. Dry ingredients are blended with raw milk in liquefier; cream is added without agitation.3. Raw milk is pumped to MT#11 (A or B) to thoroughly blend (Temp?)4. Mix is pasteurized at 179-181°F for 15-16 sec (low speed); exits HTST at 45-52°F.5. Mix is homogenized at 2500psi.6. Pasteurized mix is aged at 30-35°F for 24hrs; pasteurized yogurt is added. 7. Liquid ingredients (i.e. flavoring, coloring) are added.8. Freezing (80% overrun, 21-29°F. 9. Insufficiently frozen mix is collected and returned to flavor vats for reworking. 10. Solid ingredients (i.e. fruit) are added. 11. Frozen, flavored mix is sent to filling machines.12. Code date: 180 days from freezing date- bulk containers are hand stamped with date and product name; ½ gallons are ink-jet dated.13. Hardening (-20 to -25°F). for 12-14 hours.

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

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Sherbet

Product SherbetPlant Penn State Berkey Creamery

Ingredients Lowfat milk, skim milk, water, cream, sugar, dry corn syrup

solids, stabilizer, liquid flavoringPackaging Packaged in quarts and 3gal bulk

containersStorage and Distribution Stored and distributed under

refrigeration below (-25°F)Intended Consumer Penn State Berkey Creamery

Shelf Life 150 days from freezing date

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Sherbet Production

Blending(1)Water

SugarDry Corn

Syrup Solids

Stabilizer

Cream Lowfat Milk Skim Milk

Batching(2)

Pasteurizing(3)

Homogenizing(4)

Aging(5)

Liquid Flavoring(6)

Liquid Ingredients

Freezing(7)Air Rework

(8)

Filling(9)

Code Dating(10)

Hardening(11)

*


1qt Cartons3gal Bulk

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 179-181°F for 15-16sec (low speed); exits HTST at 45-52°F.4. Mix is homogenized at 2500psi.5. Pasteurized mix is aged at 30-35°F for 24hrs; pasteurized yogurt is added.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 date—quart and bulk containers are hand stamped with date and product name.11. Hardening (-20 to -25°F) for 12-24 hours.

* Sample taken for standard Plate, Coliform, and Yeast and Mold Tests (monthly phosphatase test on sherbet mix).

Page 41 of 45


Vanilla Soft Serve Frozen Yogurt

Product Vanilla Soft Serve Frozen YogurtPlant Penn State Berkey Creamery

Ingredients Milk, skim milk powder, sugar, stabilizer, yogurt

Packaging Packaged in 2.5 gallon bag-in-box containers


Intended Consumer University dining hallsShelf Life 30 days from processing date

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Vanilla FrozenYogurt Production

Raw MilkReceiving

(1)

Blending(2)

Batching(3)

Pasteurizing(4)

Cooling(6)*

Filling(7)

Code Dating(8)

RefrigeratedStorage

(9)

Skim Milk Powder

Stabilizer

Sugar

Cream

PasteurizeYogurt

6gal Bag-in-Box

Homogenizing(5)

1. Raw milk is received according to Raw Milk Receiving Flow Chart.2. Dry ingredients are blended with raw milk in liquefier; pasteurized cream is added under no agitation. 3. Raw milk is pumped to MT #11 (A or B) to thoroughly blend.4. Mix is pasteurized at 179-181°F for 15-16 sec (low speed); exits HTST at 45-52°F.5. Mix homogenized at 2500psi.6. Pasteurized mix is cooled in PT#10 or cream Vat to 30-35°F.7. Pasteurized mix is sent to bag in box filler.8. Product is tagged with product name and code date (30 days from processing date).9. Packaged product is stored at 35-40°F.

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

Page 43 of 45


Chocolate Soft Serve Frozen Yogurt

Product Chocolate Soft Serve Frozen YogurtPlant Penn State Berkey Creamery

Ingredients Milk, skim milk powder, cocoa, sugar, stabilizer, yogurt

Packaging 2.5 gallon bag-in-box containersStorage and Distribution Stored and distributed under

refrigeration below 40°FIntended Consumer University dining halls

Shelf Life 30 days from processing date

Page 44 of 45


Chocolate FrozenYogurt Production

Raw MilkReceiving

(1)

Blending(2)

Batching(3)

Pasteurizing(4)

Cooling(6)*

Filling(7)

Code Dating(8)

RefrigeratedStorage

(9)

Skim Milk Powder

Stabilizer

Sugar

Cream

PasteurizeYogurt

6gal Bag-in-Box

Homogenizing(5)

Cocoa

1. Raw milk is received according to Raw Milk Receiving Flow Chart.2. Dry ingredients are blended with raw milk in liquefier; pasteurized cream is added under no agitation.3. Raw milk is pumped to MT #11 (A or B) to thoroughly blend.4. Mix is pasteurized at 179-181°F for 15-16 sec (low speed); exits HTST at 45-52°F.5. Mix is homogenized at 2500psi.6. Pasteurized mix is cooled in PT#10 or Cream Vat to 30-35°F.7. Pasteurized mix is sent to bag-in-box filler. 8. Product is tagged with product name and code date (30 days from processing date).9. Product is stored at 35-40°F.

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

Page 45 of 45

Date post:	08-Apr-2016
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