Dairy processing: Aseptic processing and packaging systems
Quality control

Finished product testing

Sampling Plan

• Take statistically valid samples of the production to assess the safety and quality of the product
• Determine the quantity of containers to be taken, the tests to be performed and the standards to be met for each plan of the sampling program, based upon specifications supplied by the person responsible for the scheduled process (for example, a process authority)

Inspection of heat seals

In general, tests can be divided into 2 main types:

1. Non-destructive testing: visual inspection of seals for absence of voids, wrinkles, pleats. Other important checks to be performed include seal alignment, overlap, product contamination in seals, de-lamination.
2. Destructive testing: activation pattern using a polarisation filter, vacuum bubble test, conductivity/electrolytic test, dye penetration test, microbial challenge test, storage and distribution test, burst test, removal torque test, seal security/seal strength tests.

• Inspect heat seals at intervals of sufficient frequency to ensure consistent and reliable hermetic sealing as per manufacturer's recommendation. For example:
  • before production starts and during production
  • after jam-ups
  • as per package manufacturer's recommendation
• Use methods for these inspections that are specified by the packaging material supplier

Incubation

• Conduct incubation tests at a statistically valid frequency to verify the commercial sterility of the finished product
  • incubate samples at a specified temperature for a specific period of time to detect mesophilic growth
  • observe incubated packages for any sign of gas production (puffers), product changes such as odour, pH, oxygen content, viscosity and other indicators of spoilage, such as separation or curdling

Microbial evaluation

• Conduct microbial analysis for commercial sterility on a statistically valid number of containers from each lot (from each filling head) regardless of the absence of signs of non-sterility following incubation
• Investigate any instances of microbial growth from unsterile containers
  • pending the outcome of the investigation, detain the lot
  • record any actions taken

Product release

• Ensure all package integrity, incubation testing, processing record review and the investigation of any process deviations are satisfactory before the product is released for distribution.