Professional Documents
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Berkey Creamery
Process Flow Diagrams
Table of Contents:
Page 1 of 47
pg.3
Whole Milk
pg.4
Skim Milk
pg.6
2% Milk
pg.8
pg.10
2% Chocolate Milk
pg.12
Cream
p.14
Cheddar Cheese
pg.16
Cream Cheese
pg.19
p.21
pg.23
Yogurt
p.25
Ricotta Cheese
pg.27
Sour Cream
pg.30
pg.32
Ice Cream
pg.35
Frozen Yogurt
pg.37
Sherbet
pg.39
pg.41
pg.43
Page 2 of 47
Page 3 of 47
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
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* 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
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9.
* 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
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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
Product Name
Plant Name
Ingredients
Packaging
Storage and Distribution
Intended Consumer
Shelf Life
Page 10 of 47
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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
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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
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Page 15 of 47
Cheddar Cheese
Product Name
Plant Name
Ingredients
Packaging
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
Page 17 of 47
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
Page 19 of 47
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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.
Product Name
Plant Name
Ingredients
Packaging used
Storage and distribution
Intended Consumer
Shelf Life
Page 21 of 47
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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
Packaging
Storage and Distribution
Intended Consumer
Shelf Life
Page 23 of 47
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Page 24 of 47
Intended Consumer
Shelf Life
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
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
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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
Product Name
Plant
Ingredients
Packaging
Storage and Distribution
Intended Consumer
Shelf Life
Page 33 of 47
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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
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
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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
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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
Intended Consumer
Shelf Life
Page 43 of 47
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* Sample taken for Coliform, and Yeast and Mold Tests (and monthly phosphatase test).
Page 44 of 47
Packaging
Storage and Distribution
Intended Consumer
Shelf Life
Page 45 of 47
Page 46 of 47
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* Sample taken for Coliform, and Yeast and Mold Tests (and monthly phosphatase test).
Page 47 of 47