On the Implementation of a Food Safety System in a Small Dairy Processing Factory in State of Sao Paulo, Brazil

Introduction: The good manufacturing practices (GMPs), the sanitation standard operating procedures (SSOPs) and the hazard analysis and critical control points system (HACCP) comprehend the basis of a food safety system. In Brazil, implementation of the HACCP system in small dairies is of fundamental importance since this segment supplies dairy products to a large proportion of the population.

Purpose: The purpose of this study was to describe the implementation and costs of a food safety system in a small dairy factory.

Methods: The study was carried out in a dairy factory located in the central region of the State of São Paulo, Brazil. The steps involved in the implementation of the food safety system included a diagnosis of the prerequisites, implementation of the GMPs, SSOPs, training of the food handlers and HACCP. The total cost of implementing the systems was assessed using the method of cost appropriation (accounts for direct and indirect expenses). The total count of yeasts and molds was used to assess the impact of the implementation of food safety system in the dairy factory.

Results: In the initial diagnosis conformity with 70.7% (n=106) of the items analyzed regarding GMP was observed. A total of 12 critical control points (CCPs) were identified. After implementation of the food safety system, a significant reduction in the yeast and mold count was observed (P < 0.05). The total cost of implementing the food safety system was US$ 61,812.00, signifying an impact of US $3.81/t of yogurt packed (0.5% of the production costs). The resources used for investment signified an additional US$ 12.92/t (1.5% of the cost per kg of yogurt packed).

Significance: The implementation of the food safety system assessed in this study presented an adequate cost-benefit relationship, which would be enhanced with the improvement and sedimentation of the culture of food safety in the company.