Traceability in the dairy industry – challenges and solutions
Why is traceability of milk and dairy products so important?
Traceability in the dairy industry – just like in the entire food sector – plays a very important role. It is especially crucial in the yogurt segment. Fully tracking raw material from the moment milk is collected at the farm to the final product reaching store shelves helps ensure quality, safety, and regulatory compliance. What are the biggest traceability challenges in dairy production, and what solutions can improve the process?
Traceability challenges in dairy plants
The core idea of traceability is to record the entire journey of the product – from milk collection, through storage and processing, to the final product. Many plants still rely on paper documentation, manual records, and fragmented IT systems, making it difficult to fully track milk and dairy product batches. Let’s explore the main issues and possible improvements.
Traceability system in the dairy industry – key stages
1. Raw material delivery registration
EveEvery milk delivery to a dairy plant should be registered already at the point of collection from the producer. Currently, milk is delivered directly from farms to dairies, and its quality is assessed on-site by taking samples for analysis. Each supplier must meet specific sanitary standards. One of the key requirements is storing milk in dedicated refrigerated tanks at temperatures between +2 to +6°C, which prevents the growth of microorganisms during storage at the farm before pickup and transport to the plant.
Which parameters are assessed at this stage?
Physicochemical indicators:
- Fat content, which determines the quality and commercial value of milk;
- Protein content – extremely important for milk processing;
- Density – used to detect potential dilution of milk with water;
- Milk pH – may indicate freshness and potential microbiological contamination;
- Freezing point – helps detect any added water;
- Temperature – should typically not exceed 6°C.
Microbiological parameters:
- Total bacterial count (TBC) – reflects hygiene during milking and storage;
- Somatic cell count (SCC) – higher values indicate lower milk quality;
- Presence of pathogenic bacteria – e.g., Salmonella, Listeria monocytogenes;
- Presence of antibiotics and inhibitors – detects medication residues.
Sensory parameters:
- Smell and taste – milk should be neutral, without foreign odors;
- Color – should be white or slightly creamy.
The results of these tests determine the classification and commercial value of the milk.
2. Milk intake – tanker unloading analysis
During milk reception at the plant, samples are collected for quality analysis. Tested parameters include:
- Milk temperature – typically should not exceed 6°C;
- Smell and appearance – milk should be homogeneous, without sediment, discoloration, or foreign odors;
- Antibiotic test – rapid detection of residues that could inhibit milk fermentation (CCP);
- Inhibitor test – detects substances that inhibit bacterial growth, such as detergents and cleaning agents (CCP);
- Milk pH – should range between 6.6 and 6.8; deviations may indicate souring or contamination.
If irregularities are detected, such as the presence of antibiotics, the batch must not be unloaded and is either disposed of or classified as a category three material.
3. Milk storage and segregation
After reception, milk is stored in dedicated storage tanks and cooled to approximately 2–3°C. Each tank is equipped with an agitator to ensure uniform consistency before further processing.
4. Thermal processing and pasteurization
The first step in milk processing is pasteurization, which involves heating the raw milk to at least 72°C for several seconds. This process eliminates pathogenic microorganisms and ensures sanitary safety. At this stage, fat can also be separated, and milk composition standardized depending on production requirements.
Milk may be:
- Kept as whole milk,
- Skimmed for low-fat milk production,
- Used for cream production.
Each pasteurization step is carefully monitored and recorded to ensure full traceability.
Monitored parameters during pasteurization:
Thermal parameters:
- Pasteurization temperature depends on the process type:
- Low-temperature long-time (LTLT) – 63–65°C for 30 minutes (rarely used in industry);
- High-temperature short-time (HTST) – 72–75°C for 15–30 seconds (most common);
- Ultra-high temperature (UHT) – 135–150°C for 2 to 6 seconds (used for UHT milk);
- Temperature holding time – essential for effective microorganism elimination;
- Outlet milk temperature – post-pasteurization milk must be cooled to 2–6°C.
Flow and pressure parameters:
- Milk flow – must comply with technological assumptions to ensure sufficient thermal treatment time;
- Pressure in heat exchanger sections – pressure in the pasteurized milk section must be higher than in the raw milk section to prevent cross-contamination.
Milk quality after pasteurization:
- Presence of microorganisms – reduced bacterial count, e.g., below 10⁴ CFU/ml for consumer milk;
- Protein denaturation – should not be excessive to maintain milk properties;
- Taste, smell, and color – milk should not have burnt protein flavors or foreign odors.
5. Mixing room quality control
In facilities producing dairy products such as yogurt, kefir, or desserts, milk is directed to mixing tanks, where its fat content is standardized. Dry ingredient dosing is also monitored, depending on the recipe.
6. Dairy product manufacturing
Depending on the production plan, milk undergoes further technological processes, such as:
- Homogenization for uniform texture;
- Pasteurization or sterilization for shelf-stable products;
- Fermentation for yogurts and kefirs.
Each product batch is recorded in the traceability system, allowing tracking of ingredients, milk batches, and processing parameters. Laboratories conduct additional quality tests on the finished product, including protein, fat content, texture, and microbiological stability.
Key monitored parameters:
- Pasteurization temperature of mixtures – CCP;
- Holding time – crucial for microbial safety;
- Outlet milk temperature;
- Milk flow rate;
- Pressure in heat exchanger sections – pressure in the yogurt mixture section must be higher than in the raw milk section to prevent cross-contamination.
7. Packaging, storage, and distribution
After processing, dairy products are packed in appropriate containers. Each product receives a unique serial number and batch code, enabling full identification. Packaged finished goods are transferred to the finished product warehouse. It is crucial to maintain storage temperature within the CCP range (2°C to 6°C).
A WMS-class system helps assign a unique storage location, allowing precise product localization.
Product location and parameter data are stored in the ERP system, enabling report generation and quality monitoring for audits and compliance.
Process line preparation
Before production, installations must undergo:
1. CIP (Cleaning-In-Place): Cleans pipes, tanks, pumps, and valves while monitoring detergent concentration, temperature, flow, and time.
2. SIP (Sterilization-In-Place): Ensures microbial cleanliness by maintaining sterilization temperature and duration. All parameters are logged in ERP/MES systems.
Benefits of digitized traceability in dairy
Regulatory compliance: Eliminates manual errors with automatic data logging.
Rapid response to quality issues: Easily trace product origin for audits or recalls.
Cost optimization: Monitor material usage and reduce waste.
Transparency and safety: Real-time monitoring of all supply chain steps.
Increased efficiency and better quality: Fewer downtimes thanks to better planning and KPI analysis.
4 steps to implementing traceability in dairy plants
- Assess current infrastructure – Evaluate IT systems and data capture devices.
- Plan the budget – Include hardware, software, and integration costs.
- Train staff – Prepare employees to use new tools and maintain data standards.
- Implement automation gradually – Start with key areas like quality monitoring.
Traceability in the dairy industry isn’t just a regulatory requirement—it’s a strategic tool for improving product quality, optimizing processes, and reducing costs. Modern IT systems offer full visibility of raw materials, processing parameters, and finished goods, boosting operational performance.
Is your dairy ready for digital transformation?
Not sure how to improve traceability in your production plant? Write to us—we’ll gladly answer your questions and help you navigate the next steps.
