| Listeria monocytogenes after the kill step | Fillers, freezers, extruders, inclusion feeders, drains, condensation, cheese brining and cutting | 2.4.8 Environmental Monitoring; 11.7.1 High-Risk Processes; 11.2.5 Cleaning and Sanitation | Risk-based swab schedule (organisms, sites, frequency), results tracked and trended, corrective actions on positives, segregation of post-pasteurization areas |
|---|
| Under-pasteurization | Vat, HTST and HHST systems; ice cream mix and cheese milk | 2.4.3 Food Safety Plan (critical limits validated, 2.4.3.11); 2.5.1 Validation and Effectiveness | Validated time and temperature critical limits, recording charts, flow diversion and equipment checks, calibration records, CCP deviation records |
|---|
| Raw-to-pasteurized cross-contamination | Shared lines, valves, CIP circuits, rework | 11.7 Separation of Functions; 2.4.6 Product Rework; 11.2.5 Cleaning and Sanitation | Physical separation, CIP verification records, rework procedures that keep raw and pasteurized product apart |
|---|
| Undeclared allergens | Ice cream inclusions and variegates (peanut, tree nuts, wheat, egg, soy), flavor changeovers, rework | 2.8.1 Allergen Management; 2.6.1 Product Identification | Allergen risk analysis, validated changeover cleaning, label and packaging checks at line start, allergen-matched rework |
|---|
| Foreign material | Inclusions (nut shell, fruit pits), filler parts, metal | 11.7.3 Control of Foreign Matter Contamination; 11.7.4 Detection of Foreign Objects | Supplier specifications, metal detection or X-ray checks and reject records, glass and brittle plastic register |
|---|
| Raw milk and ingredient hazards | Raw milk receiving, dairy powders, cultures, stabilizers | 2.3.4 Approved Supplier Program; 2.4.4 Product Sampling, Inspection and Analysis | Approved supplier list, raw milk receiving checks, certificates of analysis, ISO/IEC 17025-accredited labs for external testing (2.4.4.2) |
|---|
| Temperature abuse | Cold rooms, hardening tunnels, freezers, outbound trucks | 11.6.2 Cold Storage, Freezing and Chilling of Foods | Temperature monitoring and alarm records, defrost and condensation control, loading checks |
|---|
| Water, ice and air | Product-contact water, CIP rinse, culinary steam, compressed air | 11.5 Water, Ice and Air Supply | Water and ice microbiological testing (risk-based, at least annually), backflow testing, compressed air checks |
|---|