Food Safety System (HACCP) as Quality Checkpoints in a Spin-Off Small-Scale Yogurt Processing Plant
, Mirela Jimborean 1, Iulian Rusu 1, Andruţa Mureşan 1, Alina Nistor 2,3, Angela Cozma 4 and Ramona Suharoschi 2,3,*Round 1
Reviewer 1 Report
The paper still needs improvements regarding the English language. Clarity should be improved.
In addition, some points to address are detailed below:
In the keywords, I suggest using either the acronyms or their meanings, but not both.
Abbreviation: FIS, why not FES?
Section 2.2. Please add a description of the yogurt production process. Explain why the pasteurization parameters were chosen (the temperature and time seem greater than usual).
Section 2.3.2. Please add a brief description.
Line 173: prevention of cross-contamination
Line 204: replace “sensibility” with “intolerance”
Table 3: acidity is generally expressed as %, please consider changing the unit
Table 4: I suggest omitting the phrase “qualitative and quantitative” before “reception”; in item 4, I suggest writing “milk filtration”; in item 8, delete “distribution in”; in item 7, I suggest adding “and fermentation”; in item 9, do you mean “pasteurization”?
Table 5, I think “cooling” should go before “storage”
CCP3 is sales. Does this mean the product is sold on site? This must be specified in the text.
Please ensure that all references are complete and accurate, and use the same format for all of them.
Author Response
Ms. Ref. No.: sustainability-939309
Title: Food safety system (HACCP) as quality checkpoints in a spin-off small-scale yogurt processing plant
Sustainability –MDPI – Section “Sustainable Food”; Special Issue " Safety and Quality of Sustainable Food"
On behalf of all co-authors,
I would like to thank you for taking necessary steps to improve our Manuscript in term of scientific quality. Thank you also for spending your precious time correcting our MS entitled “FOOD SAFETY SYSTEM (HACCP) AS QUALITY CHECKPOINTS IN A SPIN-OFF SMALL-SCALE YOGURT PROCESSING PLANT”. Based on your and the Reviewers’ valuable comments and suggestions, we revised our MS and we hope, the changes made in the revised MS are satisfactory.
Thank you for your confidence – according to your suggestions, we had performed amendments to our MS in order to better highlight its scientific potential.
Comments:
The paper still needs improvements regarding the English language. Clarity should be improved.
In addition, some points to address are detailed below:
In the keywords, I suggest using either the acronyms or their meanings, but not both.
Response: Keywords: yogurt; PRP; OPRP; HACCP; critical thinking model; education
Abbreviation: FIS, why not FES?
Response: corrected the whole manuscript with FES
Section 2.2. Please add a description of the yogurt production process. Explain why the pasteurization parameters were chosen (the temperature and time seem greater than usual).
Response:
Qualitative and quantitative reception of milk. Milk is transported from Cojocna farm in secured aluminium cans.
From reception valve the milk is passed in acid diary products plant (IPI tank with 100L capacity) using a pump (type 202 MHI) milk flow 2000 L / hour.
The acid diary products plant is being used for milk pasteurisation and inoculation with the starter culture.
Milk pasteurisation. Pasteurization is perferomed at high temperatures (85-90°C) for 20-30 minutes. Pasteurization aims the following:
- improvement of hygienic quality of milk;
- environement improvement for development of lactic bacteria;
- yoghurt consistency improvement: high temperatures of pasteurisation favors a softer curd that retains more whey.
From pasteurisation device the milk is continuously passed through the meanings of a pump (type MHI 202) in a heater exchanger placed above the tank until complete pasteurisation of milk. The pasteurisation is realised under continuous stirring (the valve is provided with agitator).
Milk cooling. The cooling of milk is realised in the same valve like pasteurisation by recycling the milk thorugh heat exchanger until the yoghurt reaches the temperature of 45-46°C. The heat exchanger uses water from regular city supplies network for cooling the milk.
Milk inoculation. Is realised with starter cultures of liofilised lactic bacteria. In this purpose the culture is diluted in milk and then the milk is strongly stirred until uniform distribution of culture for 10-15min. With the help of the second pump (MHI 202 type) the inoculated milk is sent to packaging device (ADL-ATS 200 type, capacity 200 – 250 cups/ hour for 200 ml cups).
Dosage in sales packaging. The dosage in sales packaging is performed in manual device (ADL-ATS 200 type). The yoghurt has to be continuously stirred in valve during packaging. The cups are thermosealed with aluminium foil after filling.
Tempering. The packaged products are placed in thermostatic aluminum cabinet (with capacity of 400 cups each 200mL). The yoghurt tempering takes place at 43-45°C for 2,5-3 hours.
Precooling at 18-20°C for 2 hours.
Cooling and storing 2-6°C for 12 hours.
Section 2.3.2. Please add a brief description.
Response: The HACCP team was responsible for coordinating and implementing the corrective measures to improve the adaptation to the PRPs (GMPs, GHPs, SSOPs). It was followed definition of the production chain—from the farm to final consumer; definition of food safety and contamination; types of contamination; importance of microbiological contamination; optimal conditions for the growth of microorganisms; contamination by microorganisms—elimination, inhibition, prevention; application of GMP's principles (personal hygiene, environment, equipment); habits for the correct handling of foods; benefits of GMP's (food safety, longer shelf-life, reduced losses, better working environment, consumer satisfaction); need to change the behavior and commitment of all employees; work instructions; importance of hygiene (how to avoid contamination); conditions for an effective cleaning; phases of the hygiene process; presentation of work instructions, as described by Cusato [20].
Line 173: prevention of cross-contamination
Response: corrected
Line 204: replace “sensibility” with “intolerance”
Response: corrected
Table 3: acidity is generally expressed as %, please consider changing the unit
Response: corrected - titrable acidity min 0.6% lactic acid (% m/m)
Table 4: I suggest omitting the phrase “qualitative and quantitative” before “reception”; in item 4, I suggest writing “milk filtration”; in item 8, delete “distribution in”; in item 7, I suggest adding “and fermentation”; in item 9, do you mean “pasteurization”?
Response:
“qualitative and quantitative” before “reception” – corrected
“milk filtration” – corrected
“distribution in” – corrected
“and fermentation” – corrected
in item 9, do you mean “pasteurization”? - It is not pasteurization. Tempering - operation of maintaining a constant temperature in a container ( in this case 44-45°C, 3 h)
Table 5, I think “cooling” should go before “storage”
Response: corrected
CCP3 is sales. Does this mean the product is sold on site? This must be specified in the text.
Response: The product is sold at the university store. The temperature in the storage refrigerator is between 2-8 ° C (Table 3, item 12).
Please ensure that all references are complete and accurate, and use the same format for all of them.
Response: corrected (Reference 3,4,9,12,13,20,32,35,38,39,41,44)
All changes are marked as highlighted red letters in the revised MS.
We are grateful for your competent suggestions! Thank you for your patience and time!
Cluj-Napoca, 26.10.2020
Yours sincerely,
Mureşan et al.
Author Response File: 
Author Response.pdf
Reviewer 2 Report
The article presents the exposition of the drafting of the HACCP protocol for the production of yogurt.
Although the points of this process have been correctly explained and discussed, I do not believe that this article brings any new element as regards food hygiene, sustainability or the production processes for the manufacture of yogurt.
The article contain the same information that we can found in a good developped HACCP manual of a dairy food factory and even if all the information presented are correct I don't think that it is suitable for the pubblication in a scientific journal. Above all I don't found any aspect in this article that is linked with the aim of this journal.
Author Response
Ms. Ref. No.: sustainability-939309
Title: Food safety system (HACCP) as quality checkpoints in a spin-off small-scale yogurt processing plant
Sustainability –MDPI – Section “Sustainable Food”; Special Issue " Safety and Quality of Sustainable Food"
On behalf of all co-authors,
I would like to thank you for spending your precious time correcting our MS entitled “FOOD SAFETY SYSTEM (HACCP) AS QUALITY CHECKPOINTS IN A SPIN-OFF SMALL-SCALE YOGURT PROCESSING PLANT”.
The authors of the manuscript "Food safety system (HACCP) as quality checkpoints in a spin-off small-scale yogurt processing plant" describe the implementation of a food safety system in the dairy pilot plant “Gourmeticus Academicum”, a spin-off within the University of Agricultural Sciences and Veterinary Medicine of Cluj Napoca, Romania. The topic is of relevant importance for the dairy industry since it pursues to identify and reduce risks during the production system, as well as obtain an increased efficiency in the manufacturing process. In addition to the aforementioned facts, the practical results related to the microbiological part and the acquired skills during the training program of future professionals in the area are of fundamental importance.
Based on the Reviewers’ valuable comments and suggestions, we revised our MS and we hope, the changes made in the revised MS are satisfactory in order to better highlight its scientific potential.
All changes are marked as highlighted red letters in the revised MS.
Thank you for your patience and time!
Cluj-Napoca, 26.10.2020
Yours sincerely,
Mureşan et al.
Author Response File: Author Response.pdf
Reviewer 3 Report
The authors of the manuscript "Food safety system (HACCP) as quality checkpoints in a spin-off small-scale yogurt processing plant" describe the implementation of a food safety system in the dairy pilot plant “Gourmeticus Academicum”, a spin-off within the University of Agricultural Sciences and Veterinary Medicine of Cluj Napoca, Romania. The topic is of relevant importance for the dairy industry since it pursues to identify and reduce risks during the production system, as well as obtain an increased efficiency in the manufacturing process. In addition to the aforementioned facts, the acquired skills during the training program of future professionals in the area are of fundamental importance.
In general, the manuscript is well written, and the practical results related to the microbiological part are quite interesting after the adoption of such a procedure. In order to have some improvements of the present manuscript, minor concerns are reported in the attached file.
Comments for author File: Comments.pdf
Author Response
Ms. Ref. No.: sustainability-939309
Title: Food safety system (HACCP) as quality checkpoints in a spin-off small-scale yogurt processing plant
Sustainability –MDPI – Section “Sustainable Food”; Special Issue " Safety and Quality of Sustainable Food"
On behalf of all co-authors,
I would like to thank you for taking necessary steps to improve our Manuscript in term of scientific quality. Thank you also for spending your precious time correcting our MS entitled “FOOD SAFETY SYSTEM (HACCP) AS QUALITY CHECKPOINTS IN A SPIN-OFF SMALL-SCALE YOGURT PROCESSING PLANT”. Based on your and the Reviewers’ valuable comments and suggestions, we revised our MS and we hope, the changes made in the revised MS are satisfactory.
Thank you for your confidence – according to your suggestions, we had performed amendments to our MS in order to better highlight its scientific potential.
Comments:
The authors of the manuscript "Food safety system (HACCP) as quality checkpoints in a spin-off small-scale yogurt processing plant" describe the implementation of a food safety system in the dairy pilot plant “Gourmeticus Academicum”, a spin-off within the University of Agricultural Sciences and Veterinary Medicine of Cluj Napoca, Romania. The topic is of relevant importance for the dairy industry since it pursues to identify and reduce risks during the production system, as well as obtain an increased efficiency in the manufacturing process. In addition to the aforementioned facts, the acquired skills during the training program of future professionals in the area are of fundamental importance.
In general, the manuscript is well written, and the practical results related to the microbiological part are quite interesting after the adoption of such a procedure. In order to have some improvements of the present manuscript, minor concerns are reported in the attached file.
Response: all suggestions have been corrected
- I suggest mentioning some examples of foodborne pathogenes associated with dairy products.
Response: corrected.
Several authors have reported the outbreaks or incidents of foodborne diseases associated with dairy products: Brucellosis, Salmonella, Listeria, Clostridium botulinum [6,7,8,9]. In industrialized countries, milk and dairy are involved in 2-6% of outbreaks of foodborne diseases [10].
- Awkard. Please consider rephrasing.
Response: corrected
The classical methods regarding the hygienic quality of the finished products are inadequate to control hazards occurring at early stages of the process [11].
3.FIS Parenthesis
Response: corrected and change FIS with FES
- Which microbiological parameters?
Response: The total Colony Forming Unit (CFU), somatic cell count (SCC), Enterobacteriaceae
- paper replace with manuscris
Response: corrected
6.Where is Figure 1?
Response: I noted both figure 1 and figure 2 with Figure 2. I corrected. Figure 1 is: Critical thinking model developed and applied as educational tool to learning FSMS
- Table 1. Table or list graphic?
Response: Table
- Hight replace with high
Response: corrected
- Enterobacteriaceae – italic
Response: corrected
- Please specify which habits and behaviors were change
Response: The theoretical and practical training applied was observed by changing habits and behaviour regarding GMPs and GHPs (where to apply the principles of GMP (personal hygiene, environment, equipment); habits for the correct handling of foods; how to avoid contamination; types of surfaces to be cleaned and cleaning agents; conditions for an effective cleaning (solution concentration, water temperature, exposure time, mechanical action); phases of the hygiene process (pre-rinsing, detergent solution, rinsing, sanitizing); presentation of work instructions.
- storge replace with storage
Response:corrected
All changes are marked as highlighted red letters in the revised MS.
We are grateful for your competent suggestions! Thank you for your patience and time!
Cluj-Napoca, 26.10.2020
Yours sincerely,
Mureşan et al.
Author Response File: Author Response.pdf
Round 2
Reviewer 2 Report
Dear Authors, even if I appreciate your manuscript and your approach to the safety production of yogurt, I can not suggest your article for the pubblication in Sustainability.
First I think that you choose a inappropriate journal. I don't understand the correlation of your work and the aims of this journal. Why a correct Haccp protocol could increase the sustainability of yogurt production?
Then I don't understand your experimental plan. You didn't test nothing that isn't in normally used in a well structured yogurt processing plant. I can't see in your manuscritp the novelty of your approach in comparison with what is usually present in the food industry.
