Based on observed production challenges - such as slower fermentation times to reach target pH, along with noticeable changes in product appearance and mouthfeel - it is highly likely that the facility may be experiencing a bacteriophage (phage) attack.
Bacteriophages are viruses that specifically infect bacterial starter cultures, disrupting fermentation performance and ultimately affecting product quality and consistency. Immediate intervention and strict control measures are essential to limite impact and prevent recurrence.
RECOMMENDED CONTROL MEASURES
To effectively manage and reduce the risk of bacteriophage contamination, the following actions are recommended:
1. Raw Milk Heat Treatment
Ensure effective pasteurisation of raw milk:
* Confirm that temperature and holding times are consistently achieved.
* Regularly verify equipment calibration and performance.
* Inadequate heat treatment can allow phages to survive and enter the production process.
2. CIP System & Equipment Sanitisation
Review and validate the Cleaning-In-Place (CIP) system:
* Confirm correct detergent concentrations, temperatures, and contact times.
* Ensure all production equipment is thoroughly cleaned and sanitised.
* Pay particular attention to hard-to-clean areas (valves, pipelines, dead ends).
Important: During a suspected or confirmed phage attack, do not reuse CIP detergents if contamination is possible. Reused cleaning solutions may act as a carrier of phages, spreading contamination across the facility.
3. Air Quality & Environmental Control
* Inspect and maintain HEPA filtration systems.
* Inproves air flow management in production areas.
* Increase frequency of ambient disinfection, especially in fermentation and filling zones.
Airborne contaminaion is a known pathway for phage transmission.
4. Prevent Cross-Contamination
Implement strict controls to eliminate cross-contamination risks:
Tank Usage:
* Avoid refilling fermentation or storage tanks multiple times without proper cleaning between cycles.
Product Rework:
* Do not reintroduce dairy by-products (e.g., product lost during pumping or rejected during packaging).
* These materials may carry high phage loads and contaminate fresh batches.
SACCO TECHNOLOGICAL APPROACH: CULTURE ROTATION SYSTEM
An effective strategy for phage risk management is the rotation of starter cultrues.
Recommended Implementation:
* Start immediately with Lyofast Y 430 A.
* Integrate into a rotation system with: Lyofast Y 438 / 439 A.
This rotation helps:
* Reduce phage adaptation.
* Maintain fermentation performance.
* Improve long-term process stability.
PHAGE MONITORING AND PREVENTION SERVICE
As part of ongoing support, SACCO offers a phage monitoring service to customers in South Africa.
Servcie Overview:
* Regular phage analysis conducted in SACCO's specialised laboratory.
* Early detection and identification of phage presence.
* Proactive recommendations to prevent production disruptions.
Additional Notes:
* This service is provided at no additional cost as part of after-sales support.
* Sample shipping costs are covered by Synercore.
CONCLUSION
Bacteriophage contamination can significantly impact dairy fermentation efficiency and product quality. However, with:
* Strict hygiene and sanitation controls,
* Proper process management,
* Strategic culture rotation,
* Ongoing monitoring. . .
. . .the risks can be effectively controlled and minimised.
Early identification and rapid response remain key to maintaining consistent, high-quality production.
Attached:
* SACCO Sampling and Storage of Samples for Phage Analysis
* Specification - Lyofast Y 430 A