EXCELENT HACCP

RETAIL FOOD SYSTEMS RESEARCH CONFERENCE

WRITING A HACCP-BASED FOOD SAFETY MANAGEMENT SYSTEM (FSMS) OPERATIONS MANUAL Tuesday, January 8, 2008, 10:30 a.m. to 12:00 noon Peppermill Resort*Spa*Casino Reno, Nevada O. Peter Snyder, Jr., Ph.D. Hospitality Institute of Technology and Management 670 Transfer Road, Suite 21A; St. Paul, MN 55114 TEL 651 646 7077; FAX 651 646 5984 e-mail: [email protected] web site: http://www.hi-tm.com

presentations: RENO2008: Jan08-Tue-writing rev 1/2/08 3:09 PM print 1/2/08

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THE UNIT AS A FOOD PROCESS SYSTEM


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FOOD SAFETY MANAGEMENT SYSTEM (TRAINING) MANUAL Preface Log of changes Reassessment Operations Description System description Organization Environment (picture) Facilities (plan) Equipment (list) Menu HACCP (processes) AMC-HACCP Management Food safety policy Responsibility and accountability HACCP team / QC Self-inspection Corrective action Training Emergencies Food security / sabotage


Prerequisite Processes Personal hygiene Employee illness reporting Hand washing After toilet After touching raw food Facilities, Environment Cleaning, maintenance, and pest control Equipment Cleaning and maintenance of food contact surfaces Supplies Source of supply Ingredients Supplier safe vs. cook made safe Receiving inspection Storage: ambient, refrigerated, frozen Control of physical, chemical, and biological contamination 3

Food Process HACCP Pre-preparation Physical hazards Chemical hazards Allergens Thawing Fruit and vegetable washing Serving raw food Preparation Salad and hors d'oeuvres Pasteurization / sterilization Ingredients to extend shelf life Hot holding Cooling Cold holding Leftovers / reprocessing Distributing / serving food Communicating safe handling

PROCESS PERFORMANCE CRITERIA-BASED AMC-HACCP SELF-INSPECTION FOOD SAFETY PERFORMANCE REQUIREMENTS 1. Management, Person In Charge (PIC) a. Self-assessment using hazard and control checklist b. Cooks trained, know hazards and perform controls and monitoring c. HACCP team trained and meeting to verify records that processes are in control and to take corrective action and improve d. HACCP plan validated and being followed Prerequisite Programs 2. Personal Hygiene a. Ill employee control (no work if vomiting, diarrhea; tell PIC if sick; restricted work if sneezing, coughing, runny nose; Call health department with hepatitis A, norovirus, Salmonella, Escherichia coli O157:H7, etc.) b. Hand sink is convenient, equipped, stocked c. Employees clean (uniform; no body odor, short fingernails, etc.) d. Double hand washing when coming into food prep area, 6 log reduction; Single hand washing when in kitchen working with food, 3 log reduction e. Gloves covered bandaged wounds and cuts on hands; changed as necessary 3. Environment / Facilities a. Cleaned, maintained, pests controlled b. Water, plumbing, sewage, trash controlled (no cross connections; backflow preventers / air gaps installed; water safe source; approved sewer and waste management) c. Toxic items, chemicals controlled (separate storage; labeled) 4. Equipment a. Thermostats calibrated b. Adequate capacity to process food (Cook, hot hold, cool, cold hold) c. Safe construction materials d. Food contact surface rinse, wash, rinse, sanitize, 5 log reduction e. Maintained 5. Food Source, Receiving, and Storage a. Sources provide intervention strategies for ready-to-eat food b. Food received ≤41ºF or 0ºF, undamaged / unspoiled or rejected c. Stored, covered, raw on bottom, ready-to-eat on top ≤41ºF; 0ºF; cool dry; 6 inches above floor d. Chemicals separated; rejected supplies separated Food HACCP Processes 1. Physical hazards reduced to an appropriate level 2. Allergen control; know ingredients; do not add fresh to old 3. Additives used according to CFRs 4. Consumer advisory 5. Double washing fruits and vegetables, 2 log reduction; or blanch, 5 log reduction 6. Freezing for parasite destruction (-4ºF, 7 days) 7. Cooking pasteurization, >5 log Salmonella reduction; roasts 6.5 log reduction 8. Hot hold, transport, serve / catering >130ºF or <1 log increase in pathogens 9. Inhibitors for spore pathogen control: pH <4.2, aw <0.92 Vegetative pathogen control: pH <4.2, aw <0.86 10. Cooling, <2 inches thick, <1 gallon, <1 log increase in Clostridium perfringens 11. Cold hold <7 days, transport, serve / catering, <1 log increase in pathogens (Bacillus cereus); fresh not added to old 12. Salads mixed with ingredients, <50ºF for Staphylococcus aureus toxin control 13. Leftovers reheat to 165ºF, <2 hours, hold 15 seconds 14. Take out: Customers advised to eat in <4 hours or refrigerate immediately (<3 log increase Bacillus cereus)


OBSERVATION

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CORR. ACT.

FDA FOOD SAFETY MANAGEMENT HACCP DOCUMENT AMC-HACCP VALIDATION OF THE SAFETY OF _________________________________________ (Name and address of establishment) (Report prepared by _________) TABLE OF CONTENTS Summary Introduction to the process Recipe, flow chart Experimental validation data HACCP plan Process step Significant hazard identification Control validation data Monitoring, frequency, method, records Corrective action if critical limits are not met Verification by PIC that HACCP plan is properly operated Training presentations: RENO2008: Jan08-Tue-writing rev 1/2/08 3:09 PM print 1/2/08

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HACCP-TQM RETAIL FOOD SYSTEM Food market

Restaurant

Home

Management Continuous HACCP Improvement

INPUT, Baseline Hazards H0 Prerequisite Processes Personnel with disease Environmental hazards Pests, insects, birds Water contaminated with microorganisms, and at a high pH >8.0 Gas, solar, electric. water that can be interrupted Facilities and equipment cleaning and maintenance Supplies and material with environmental and human hazards, contamination, various levels of nutrients and spoilage, receive and store

FOOD HACCP PROCESS, + ΣI - ΣR Reduce hazard to a TLR / ALOP*

Food processes I. Wash / trim, serve II. Fermented, pH, aw preserved food: cheese, yogurt, wine, sauerkraut, cider, cold smoked, dressing, salt, acid, etc. III. Pasteurized, serve Meat, fish, poultry, vegetable, starch IV. Pasteurized and pH / aw preserved: fruit / jams; BBQ; meat, poultry; salted / smoked fish, sausage; tomato, hollandaise sauce; bread, pastry V. Sterilized

Daily Operations Report

OUTPUT, FSO* Food with TLR / ALOP* Serve -- carry-out Transport / package Consumer Food with a good balance among pleasure, safety, nutrition, convenience Consumer food abuse Consumer allergies, intolerance, etc. Waste Heat, contaminated air, smoke, grease Sewage, graywater Glass, paper, metal, plastic Food, grease

Leftovers TLR = Tolerable Level of Risk


ALOP = Appropriate Level Of Protection

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FSO = Food Safety Objective

RETAIL FOOD BIOLOGICAL HAZARDS Vegetative. cells (Reduce) Campylobacter jejuni, other campylobacters Diarrheagenic Escherichia coli Listeria monocytogenes Salmonella Staphylococcus aureus Shigella Vibrio Yersinia enterocolitica and Y. pseudotuberculosis Other Bacterial Pathogens: Aeromonas Arcobacter Nitrobacteria Helicobacter Mycobacterium Plesiomonas Streptococcus, and others

Spores (Prevent Germination) Bacillus cereus and other Bacillus spp. Clostridium botulinum Clostridium perfringens Clostridium difficile


Parasites (Reduce)

Viruses (Reduce)

Giardia Entamoeba histolytica Cryptosporidium parvum Toxoplasma gondii Trichinella Cyclospora cayetanensis Anisakis sp. and related worms Diphyllobothrium spp. Nanophyetus spp. Acanthamoeba and other free-living amoebae Ascaris lumbricoides Trichuris trichiura and others

Hepatitis A virus Hepatitis E virus Norovirus Other Enteric viruses Rotaviruses, and others

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Biological Toxins (Prevent) Staphylococcus aureus Bacillus cereus Clostridium botulinum

Seafood toxins (Prevent) Scombroid

RETAIL FOOD CHEMICAL HAZARDS (Prevent / Eliminate) Biogenic Amines, Toxins Histamine Ciguatera Paralytic shellfish poison Neurotoxic shellfish poison Amnesic shellfish poison Tyramine Serotonin Catecholamine neurotransmitters Tryptamine

Toxins & Natural Chemicals, Fungal & Mushroom Toxins Lead Mercury Radionucleides

Allergens and Intolerance Milk Eggs Wheat Peanuts Soy Tree nuts Fish Crustacean shellfish

Other Natural Toxins Pyrrolizidine alkaloids Phytohaemagglutinin (Red kidney bean poisoning) Grayanotoxin (Honey intoxication), and others

Residues Pesticides, herbicides, hormones, antibiotics

Prions nCJD

RETAIL FOOD PHYSICAL HAZARDS (Reduce) Broken Teeth Bones Rocks Metal Twist ties / staples Pits / seeds

Choking Plastic Wrap Large, insufficiently chewed pieces of food


Cuts in Mouth Glass

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Burns Temperature of foods above 170ºF (77ºC)

TOXIC COMPOUNDS IN FOOD Mycotoxins in grain Kidney beans Soybeans Raw egg whites Mushrooms Potatoes Spinach, rhubarb Taro Parsnips Flavonoids Alfalfa sprouts

Cooking does not eliminate. Must be boiled 10 minutes to reduce phytohemagglutinin to a safe level. Must be heated thoroughly to reduce heat-labile protease inhibitors. Conalbumin and avidin can impair metabolism. Can cause cancer in mice. Solanine and chaconine are heat stable. Oxalates inhibit calcium absorption. Trypsin inhibitors destroyed by heat. Carcinogenic and mutagenic psoralens not destroyed by heat. Can inhibit enzyme systems and respiration. Canavanine causes lupus disease.

Other examples of foods containing toxins: herbal teas, cottonseed; black pepper; hot pepper; oil of mustard and horseradish; heated milk protein; heated fats.


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FOOD HAZARDS (H0) AND FOOD SAFETY OBJECTIVES (FSO) Hazards

Raw Product Contamination (H0)

Process Performance Criteria (ΣR)

Food Safety Objective (FSO)

103 cfu/g 106 cfu/g

10-5 cfu/g - reduce 10-6 cfu/g - reduce

10-2 cfu/g or 1cfu per 100 g 10 cfu/g or 1cfu

MICROBIOLOGICAL (Reduce) INFECTIVE Vegetative pathogens - infection Salmonella spp. / E. coli O157:H7 (food) Shigella spp. (feces) (human) Parasites Cryptosporidium parvum (food) Toxoplasma gondii (food) Trichinella spiralis (food) Viruses Hepatitis A (human) Norovirus (human)

1 cyst 1 cyst 1-500 larvae

prevent / reduce prevent / reduce prevent / reduce

undetectable undetectable undetectable

>10 virus / g >100 virus / g

prevent / reduce prevent / reduce

undetectable undetectable

TOXIN PRODUCING Staphylococcus aureus (exotoxin) (human)

103 cfu/g

<103 cfu/g increase

<106 cfu/g (toxin dose: <1 microgram)

100 spores / g 102 spores / g 102 spores / g

<103 cfu/g increase <103 cfu/g increase <103 cfu/g increase

<103 cfu/g (toxin dose: ≤2 nanograms) <105 cfu/g (toxin dose: unknown) <105 cfu/g (toxin dose: unknown)

Sulfites Nitrates Nitrites Monosodium glutamate

Variable Variable Variable Variable

none added <500 ppm added <200 ppm added ≤0.5 g / serving added

<10 ppm <500 ppm <200 ppm <3.0 g / meal

Aflatoxins (from mold) Histamine (from fish, cheese)

<20 ppb <20 ppm

no increase no increase

<20 ppb <20 ppm

>1/16 inch diameter >1/4 inch diameter

prevent / remove cut ≤1/4 inch

undetectable <1/4 inch

SPORES Clostridium botulinum (exotoxin) (food) Bacillus cereus (exotoxin, enterotoxin) (food) Clostridium perfringens (enterotoxin) (food)

CHEMICAL (Prevent / eliminate)

PHYSICAL (Prevent / eliminate) Hard foreign objects (broken tooth) Choking * cfu = colony forming units


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VEGETATIVE BACTERIAL PATHOGENS (5-log / 6.5-log Pasteurization or 2-log Wash) Bacteria Aeromonas hydrophila Listeria monocytogenes Yersinia enterocolitica Salmonella spp. Shigella spp.

Source

Vibrio parahaemolyticus Vibrio vulnificus Campylobacter jejuni

Feces / food Feces / food Feces / food Feces / food Feces / food / water Feces / food / water Feces / food / water Seafood / water Seafood / water Feces / food

Staphylococcus aureus growth toxin production

Nasal cavity, skin, infected cuts, boils, wounds

Escherichia coli O157:H7 Vibrio cholerae


Min. temp. (°F) 29.3 29.3 29.3 41.4 43

Max. temp. (°F) 111 113 111 115.2 116.8

Min. pH

Max. pH

Min aw

4.0 4.4 4.2 4.2 4.8

7.2 9.4 10 8.0 9.3

.92 .945 .94 .96

Time 1-log reduction at 140°F (minutes) 0.02 m. 3.8 m. 1.6 m. 1.7 m. 1.7 m.

44.6

114

4.0

9.0

.95

1.7 m.

n/a

50

109.4

5.0

10

.97

D120 =8.15 m.

n/a

41 46.4 86

111 109.4 113

4.8 5.0 4.9

11 10 9.3

.94 .96 .987

D120 =0.82 m. D122 =0.66 m. 0.25 m.

n/a n/a n/a

44.6 50.0

122 118

4.0 4.5

10 9.8

.83 .86

3 m.

11

Toxin Destruction n/a n/a n/a n/a n/a

68.6 minutes at 210°F

SPORE-FORMING BACTERIAL PATHOGENS - VEGETATIVE STATE Bacteria Clostridium perfringens

Bacillus cereus

Clostridium botulinum, type A, and proteolytic B and F Clostridium botulinum, type E, and nonproteolytic B and F

Source Soil, feces, sewage, water, dust Soil, dust, grains, cereals

Soil

Water, sludge near bodies of water


Min. Max. temp. temp. (°F) (°F) 50

39.2

125

122

Min. pH

Max. pH

Min aw

5.5

9.0

.93

4.3

9.3

.92

Time for veg. cell D-value (°F) destruction Spores at 140°F (minutes) 3.5 m. D210°F = 31.4 min. Beef Gravy (varies with type) D212°F = 3.1 1 m. min. Skim milk D212°F = 22 to 36 min. in rice

50

118.4

4.6

9.0

.935

D250°F = Not available 0.23 to 0.3 min.

37.9

113

5.0

9.0

.97

Not available

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D180°F = 0.8 to 6.6 min. (depending on type of food.)

Toxin Destruction n/a

D132.8°F = 5 min for diarrheal illness D250°F = 90 min for emetic illness D174°F = 20 min. D185°F = 5 min. (same as above)

FOOD PROCESS HAZARD ANALYSIS HAZARD ANALYSIS Purchasing (H0) Receiving-Storage

Infective vegetative bacteria, viruses, and parasites found in meat, poultry, milk, vegetables, fruit, etc. Illness Dose (FSO*) Salmonella spp. 4 to 105 CFU Vibrio spp. 103 to 1010 CFU Campylobacter jejuni 400 to 500 CFU Shigella spp. 10 to 100 CFU E. coli O157:H7 10 to 100 CFU E. coli (enterotoxigenic) 106 to 1010 CFU Listeria monocytogenes 100 to 1000 CFU Hepatitis A, norovirus, <10 Parasites, tapeworms, <10 round worms, flukes

Chemicals, poisons, poisonous plants found in meat, fish, vegetables, casseroles, and sauces Biological Toxins Illness Dose (FSO*) Staphylococcal toxin 105 to 106 CFU/g (for toxin amount) Botulinal toxin 103 CFU/g Scombroid toxin (histamine) >50 mg/100g Fish Poisons Ciguatera poisoning >1 mg. toxin Paralytic shellfish poisoning >80 µg/100g Chemicals Monosodium glutamate >0.5% (Amt. in food) Sulfites >10 ppm (Amt. in food) Nitrate and nitrites >200 ppm (Amt. in food)

Spores found in meat, milk, vegetables, starches, cereals, and sauces Clostridium perfringens Clostridium botulinum Bacillus cereus

Illness Dose (FSO) 106 CFU 103 CFU/g (for toxin hazard) 105 - 1011 CFU (for toxin and diarrhea hazard)

Spores are not a hazard until the process allows the spores to germinate and multiply

PROCESS CONTROL Preparation Thaw Cut Wash

Cold handling

Cook – hot

30 to 115ºF veg. path. mult. Increases hazard Washing fruits and vegetables

Competitive microorganisms and time prevent significant increase. Pasteurize, 5-log reduction. Veg. path. destroyed. Cool. Only spore hazard; veg. path. destroyed <40ºF – no veg. path. hazard Prevent crosscontamination

reduces hazards Cook

Post-cook process

Leftovers Reheat not required for safety

30 to 115ºF veg. path. mult. increases hazard

30 to 115ºF veg. path. mult. increases hazard Prevent cross-contamination

Cold handling Hazardous

Cook – hot Hazardous

Cold handling No hazard

Cook – hot <6 hours to ≥130ºF Spores activated but then, killed above 130°F

Hazardous

Hazardous

No hazard

Hazardous

Hazardous

No hazard

Hot hold >130ºF, no hazard Cooling <6 hours, 120 to 55ºF – no hazard <41ºF – no hazard

*FSO = Food Safety Objective


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RETAIL HACCP PROCESS PERFORMANCE CRITERIA PREREQUISITE PROCESSES HACCP Risk SystemÆProcesses H0 + ΣI - ΣR = FSO / ALOP Critical Process Sick employees Strep throat: -Cough into shoulder for 3-log reduction of Streptococcus pyrogenes Feces on fingertips: -Double wash fingers coming from toilet and bowel movement, 6-log Shigella reduction Facility / environment Contaminated water: -EPA standards for chlorine and 3-log reduction of viruses and parasites by filtration Equipment Contaminated non-food contact surface: -Wash and rinse to visually clean <100 CFU / 50 sq. cm. -Wipe scraps from food contact surface; wiping cloth in sanitizer solution Contaminated food contact surface: -Wash, rinse, sanitize – 5-log reduction E. coli (2 buckets, 3-compartment sink, dish machine) Equipment controls inaccurate: -Calibrate and maintain Supplies Cleaning and pest control chemicals: -Secure chemicals Ingredients (allergens, additives): -Use IAW GMP / approved levels Physical hazards: -Reduce to <1/16 inch or small enough not to cause choking Pathogens in vegetables and fruit: -No temperature requirement (no rapid and progress growth) -Double Meat, poultry, control spoilage: -Fish, control histamine


Hazard Name

Sev

Det

Proc Freq

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H0 Level

FSO

Critical Limit

Perf Crit

HAND WASHING HACCP Hazard: Toilet paper slips and tears, and a person can get 6 log pathogens on fingertips. Control: When coming from the toilet, do the double wash with a nail brush for a 6 log reduction by dilution. 1. Nail brush friction, detergent, and water (45 to 110ºF), 3 log reduction 2. Second wash, no nail brush, 2 log reduction 3. Paper towel dry, 1 log reduction 4. Water flow, no splash, 2 gallons / minute 5. No touch controls are not necessary Validation: 1. Contaminate fingertips 7 log with nonpathogenic E. coli 2. Double fingertip wash, 6 log reduction 3. Petrifilm™ recovery E. coli <10 total


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KITCHEN CLEANING AND SANITATION FOR LISTERIA CONTROL

HAZARD: It must be assumed that the kitchen environment will be colonized with Listeria monocytogenes (Lm). The food contact surfaces in the cook-chill assembly and packaging departments for ready-to-eat food must be cleaned so that there is no measurable Lm (<1 CFU / 25 grams of food). CONTROL 1. Determine the niches in the equipment in the ready-to-eat assembly and packaging areas where Lm might become colonized. 2. Establish a cleaning plan for this area. 3. Chose a control alternative a. Add a Lm chemical growth inhibitor such as sodium diacetate or potassium lactate and also, do a postpackage heat treatment. b. Just add the chemical inhibitor. c. Use sanitation measures only. This is the best for retail, because it does not affect the product. VALIDATION: Monthly, take 1 to 3 sponge samples of food contact surfaces and 1 to 3 samples of environmental surfaces (e.g., floor drains, scrubbies, floor scrubbers) and test for Listeria innocua. Follow the action flow chart, FSIS Dir 10,240.3. presentations: RENO2008: Jan08-Tue-writing rev 1/2/08 3:09 PM print 1/2/08

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FLOW CHART OF LISTERIA CONTROL IN READY-TO-EAT FOOD PRODUCTION ROOM FSIS DIRECTIVE 10,240.3

Day 1 1 week of month: Take samples for Listeria spp. 1-3 FCS (Food Contact Surface) 1-3 Environment – If environment is positive, do environmental samples until 9 in a row are negative. st

Day 2

Day 4 Negative Day 1 FCS sample, Listeria spp.: Continue to operate. Day Day Positive Day 1 FCS sample, 3 5 Listeria spp.: Clean, sanitize. Take 2 FCS samples for Listeria spp. Produce product.

Day 7 Negative Listeria spp. Day 4 FCS: Release Day 4, 5, 6 product. Continue to Day operate. 6 Positive Listeria spp. Day 4 FCS, destroy product; best corrective action.

t Ship product

Hold product If Day 4 test is positive for Listeria spp. on Day 7, test lots for Listeria monocytogenes (takes 3 days; best to destroy)


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If negative Listeria monocytogenes test on Day 7, ship. If positive, once can do more testing, but cook or destroy is recommended. .

FOOD CONTACT SURFACE WASHING HACCP (cutting boards, knives) Hazard: Campylobacter jejuni from chicken (1,000 to 10,000 on surface) and Vibrio from seafood Control: 1. With warm water running over the cutting board into a disposal, scrub with a brush for a few seconds; 3 log reduction by dilution 2. In the pot and pan sink, scrub again; 2 log reduction by dilution 3. Rinse to remove soap 4. Sanitize, air dry Validation: 1. Put 7 log E. coli on the cutting board 2. Wash and sanitize 3. Swab 8 square inches, <10 E. coli


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FOOD RECEIVING AND STORAGE HACCP Hazard: Pathogens from raw food can cross-contaminate ready-to-eat food. Control: • Raw food: time and temperature not CCP; washing or cooking makes food safe • Ready-to-eat food on top • Air flow: 50 feet per minute holding; 1,000 feet per minute cooling; 41ºF, 7 days; 45ºF, 4 days; 50ºF, 2.5 days; 70ºF, 18 hours; 110ºF, 4 hours • Humidity 70% to prevent mold growth; 95% to prevent drying of fruits and vegetables Validation: • Instant mashed potatoes with E. coli in a container; Store, measure temperature, measure growth


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FDA VS. HACCP PROCESS CONTROL STANDARDS Process Step

Receiving, storage, pre-preparation

Preparation Fruit and vegetable washing Pasteurization Meat, fish, fruits, vegetables, bakery

Poultry Hot hold, transport, serve, package Cool Packaging ready-toeat food Cold hold Shelf stable processed food Vegetative cells Spores Reheat Consumer abuse

FDA Performance Standard

HACCP Performance Standard / Criterion

41ºF.

Not a CCP. Receive at any temperature. 5D cooking reduces vegetative pathogens on meat, poultry, and fish to a tolerable level. Growth of pathogens on raw vegetables not an identified significant hazards. If food is to be served without washing or pasteurization, the supplier assures safety.

None.

2D wash E. coli reduction; 5D surface blanch E. coli reduction.

130ºF, 112 min.: beef 135ºF, 27 min.; 140ºF, 9 min.; 145ºF, 3 min.; 150ºF, 1 min.; 155ºF, 15 sec. 165ºF, 15 sec. 130ºF beef; 135ºF everything else.

5D Salmonella (E. coli) reduction.

135 to 70ºF, 2 hr.; 70 to 41ºF, 4 hr. None. 41ºF, 7 days.

<4.6 pH C. botulinum, <0.86 aw Staphylococcus aureus. 41 to 165ºF, 15 sec., 2 hr. None.


<1-log increase Clostridium perfringens, which begins to multiply ~125ºF, and at 105ºF, multiply every 15 min. 120 to 55ºF, 6 hr. and continue to 40ºF (14.2 hr.) or <1-log increase of C. perfringens or Bacillus cereus (USDA). No detectable Listeria monocytogenes (<1 / 25 g) in ~3 samples every 3 months. No standard. Until spoiled. <50ºF Clostridium botulinum control, <40ºF B. cereus control.

<4.2 pH Salmonella, <0.86 aw Staphylococcus aureus. <4.6 pH C. botulinum, <4.2 pH B. cereus, <0.92 aw B. cereus. No standard. Control not needed. <3-log increase B. cereus. 20

SUPPLIER CONTROLS FOR SAFE PRODUCTS CONTROL INGREDIENT

Grown Safe

HFO Sort, Remove

Wash

STABILIZE

Pasteurize Sterilize

Allergen (inform)

Meat / poultry / fish / seafood Entrée / specialty foods Dairy / egg products Bakery products Grain / mill products Nuts Fruits / vegetables Non-alcoholic beverages / juice / bottled water / other drinks Fats / oils Sugars / sweeteners / confections Condiments / salad dressings / vinegars Gravies / sauces / soups Spices / flavorings / food chemicals Gelatins / puddings / dessert powders Alcoholic beverages / bar mixes presentations: RENO2008: Jan08-Tue-writing rev 1/2/08 3:09 PM print 1/2/08

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Other

Aw

pH Acid / Ferment

Ref. / Freeze

COOK CONTROLS FOR SAFE PRODUCTS INGREDIENT

B,C,P Hazard

HFO Sort, Remove

CONTROL Pasteurize Wash Sterilize

Meat / poultry / fish / seafood Entrée / specialty foods Dairy / egg products Bakery products Grain / mill products Nuts Fruits / vegetables Non-alcoholic beverages / juice / bottled water / other drinks Fats / oils Sugars / sweeteners / confections Condiments / salad dressings / vinegars Gravies / sauces / soups Spices / flavorings / food chemicals Gelatins / puddings / dessert powders Alcoholic beverages / bar mixes


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Allergen Other (inform)

Aw

STABILIZE pH Acid / Ref. / Ferment Freeze

MENU ITEM ALLERGEN ANALYSIS Big Eight Allergen Ingredients Food Intolerance Milk Food Crustaceans Tree and milk Product Peanuts Sulfites MSG Other Eggs Soy Wheat Fish byand shellfish nuts products


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PROCESS HURDLE TECHNOLOGY Physical Hurdles Heat processing (pasteurizing, blanching Storage temperature (chilling, freezing) Radiation [ultraviolet (UV), ionizing radiation (irradiation)] Electromagnetic energy, EME (microwave energy, radio frequency energy) Photodynamic inactivation Ultrahigh pressure Packaging (vacuum packaging, active packaging, edible coatings) Modified atmosphere packaging (MAP) Aseptic packaging


Physicochemical Hurdles Water activity (aw) Glucono-δ-lactone (GDL) pH Redox potential (Eh) Chelators Surface treatment Salt (NaCl) agents Nitrite (NaNO2) Ethanol Nitrate (NaNO3 or Propylene glycol KNO3) Maillard reaction Carbon dioxide products (MRPs) (CO2) Spices and herbs Oxygen (O2) Lactoperoxidase Ozone Lysozyme Organic acids Chlorine Ascorbic acid Chitosan Sulphite or SO2 Smoking Phosphates

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POTENTIALLY HAZARDOUS FOOD / TEMPERATURE CONTROL FOR SAFETY The goal is to measure and control the process capability to the time of consumption, to achieve the following food safety objectives: Vegetative Cells Staphylococcus aureus <3 log growth or no detectable toxin; H0 ≤2 log in ready-to-eat food Listeria monocytogenes <1 log growth (Ross says ≤100 / gram at consumption) Salmonella
pH 4.8 4.8 4.9 5.0 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 6.0 6.1 6.2 7.0

aw 0.990 0.955 0.935 0.920 0.913 0.907 0.902 0.900 0.898

Appendix C:

Spores Bacillus cereus ≤3 log growth; H0 ≤2 log pathogenic / gram Clostridium perfringens ≤3 log growth; H0 ≤2 log pathogenic / gram Clostridium botulinum (C. sporogenes proxy) absence of toxin (probably ≤3 log growth)

aw 1.000 0.988 0.978 0.973 0.968 0.964 0.961 0.958 0.955 0.953 0.951 0.950 0.949 0.948 0.947 0.946 0.946

Graphs adapted from: Evaluation and Definition of Potentially Hazardous Foods Scientific Data Used to Develop Framework 1. Determination of pH and water activity limits for TCS foods


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http://www.cfsan.fda.gov/~comm/ift4-ac.html

pH PROCESS CONTROL pH 14.0 10.0 9.0 8.5 8.0 7.0

6.0-7.6 6.8-4.6

6.8-6.5 <5.0 <4.6

<4.5 <4.2-4.0 4.0 2.0-3.0 1.0-2.0

Description Very alkaline Dishwashing chemicals, Milk of Magnesia, vegetative pathogen death Upper growth limit for bacteria (>9.0 bacterial destruction) City water Alkaline Egg white, hominy, devil's food cake Neutral Soaps, hand wash detergents Can cook in copper Human saliva Low acid Most vegetables (corn, peas, potatoes, beans, lettuce), melons, meat, fish lobster, poultry, milk, cream, oatmeal, gravy, bread Chlorine sanitizer 100% effective Clostridium perfringens and Clostridium botulinum type E stop growing Acid Most fruits (apples, oranges, grapes, berries, pineapple, tomatoes), Jell-O Clostridium botulinum types A and proteolytic B growth is stopped Staphylococcus aureus toxin production stopped Bacillus cereus, Salmonella, Escherichia coli, and Listeria monocytogenes stopped BBQ sauce, catsup, mayonnaise, mustard, hollandaise sauce, pickles, jams and jellies, pickled pig's feet, carbonated beverages Lemons, limes, cranberry juice, vinegar Very acid Digestive, hydrochloric acid of the stomach


26

WATER ACTIVITY (aw) PROCESS CONTROL Minimal aw required for Bacterial, Yeast, and Mold Growth No restriction

Yersinia enterocolitica 0.975 Campylobacter spp. >0.97 Clostridium botulinum, type E 0.97 Clostridium perfringens 0.93-0.95 Bacillus cereus 0.93-0.95 Salmonella spp. 0.92–0.95 Escherichia coli O157:H7 0.95 Clostridium botulinum, type A 0.94 Listeria monocytogenes 0.90–0.93 Vibrio spp. 0.93 Most bacteria 0.91–0.88 Most yeasts 0.88 Staphylococcus aureus 0.83 Toxin production 0.86 Regular molds 0.80 Halophilic bacteria 0.75 Xerotolerant molds 0.71 Xerophilic molds and osmophilic yeasts 0.62-0.60 No microbial proliferation (growth)


Water activity 1.0 >0.98

Food

0.98 to 0.95

Water Fresh meats, poultry, fish Fresh fruits and vegetables Milk, canned fruits and vegetables. Cooked meat, fish and poultry, bread

0.95 to 0.91

Cured meat products, cheeses

0.91 to 0.87

Fermented sausages, syrups

0.87 to 0.80 0.80 to 0.75 0.75 to 0.65

Fruit juice concentrates, sweetened condensed milk, flours, rice, dried vegetables (peas, beans) Jams, marmalade Fudge, marshmallows, jelly, molasses

0.65 to 0.60

Dried fruits, caramels, honey

0.60 to 0.20

Dry pastas (vermicelli), spices, dry milk powder, dried egg powder, crackers 27

NON-HAZARDOUS-INGREDIENT PRODUCTS DO NOT REQUIRE PROCESSING BY COOK FOR SAFETY Protein Bacon bits Nut paste Peanut butter Tahini Cured meats, all Pate Caviar Egg roll, Stuffed pasta, ravioli tortellini, etc. Leftovers Gravy Soups Soup or gravy stock Dried gelatin Nuts, seeds

Dairy Cheese, hard Cheese, soft Cottage cheese Cheese cake Milk Condensed milk Cream Ice cream bar Sour cream Whipped topping Yogurt Flan Butter Evaporated milk

CHO, Starch, Sugar Bagels Bread crumb, stuffing Chips Chow mein noodles Crackers, pretzels Dry breakfast cereals Dry grains, rice, pasta Bread, rolls, buns Ice cream cone Lefse Pie shell, Pizza crust Popcorn Taco shell, Tortilla (flour or corn) Dumplings Wonton skin Candy, Chocolates Ice cream toppings Marshmallows Frozen desserts: ice cream, sherbet, ices Cookies Honey Mousse, pudding, Jello Flour Syrup Molasses


Fats, Oils Oil Pan coating Shortening

Fruit, Veg. Fruits Fruit pie fillings Fruit Juices Canned, dried and frozen fruits Jams, jellies, and preserves Vegetables Capers Chilies Horseradish Olives, Pickles Dry beans, peas, lentils, etc Tempeh, Tofu, Miso Sauerkraut Guacamole Hummus Soy milk Rice milk Cooked vegetables Sauces, tomato, etc. (ready to use) Potato products: Tater tots, hash browns, hush puppies

28

Herbs, Spices, Condiments BBQ sauce Cooking wine Garlic, canned Hot sauce Ketchup Salsa Mayonnaise Mustard Relish Salad dressings Soup base (dry) Vanilla extract Vinegar Worcestershire sauce

Funct. Addit. Dry spices Fresh herbs and spices Ginger root Pepper Salt Sugar Cornstarch

Beverages Coffee Tea Soda Alcoholic beverages Water, ice

HAZARDOUS INGREDIENTS DO REQUIRE PROCESSING BY COOK FOR SAFETY Protein Meat Uncooked meats, all (e.g., bacon)

Dairy Raw milk and any other unpasteurized dairy products

CHO, Starch, Sugar None

Fish Fish Scallops, shellfish Poultry

Other Eggs


Fats, Oils None

Fruit, Veg. Fruits, fresh Berries Citrus fruit Coconut Fruit, non-citrus Melons, all Banana Vegetables, fresh Fresh vegetables Lettuce Spinach Non-proteinbearing vegetables Onion Peppers Potatoes Vegetables, lowprotein

29

Herbs, Spices, Condiments None

Funct. Addit. None

Beverages None

RETAIL HACCP PROCESS PERFORMANCE CRITERIA FOOD PROCESS HACCP Risk SystemÆProcesses H0 + ΣI - ΣR = FSO / ALOP Critical Process

Hazard Name

Sev

Det

Proc Freq

Pre-prep Raw food bacterial growth – not CCP: -Pasteurization controls w/ 5-log reduction Salmonella RTE food: -Bacillus cereus <3-log growth, Listeria monocytogenes <2-log growth Fruit and vegetable: wash – 2-log wash / 5-log pasteurization reduction Fermentation – control of pathogens Pasteurize – use integrated lethality 5-log reduction Salmonella (meat and poultry) 5-log reduction Vibrio (fish / shellfish) Sterilize – vegetables, 12-log reduction Clostridium botulinum (250ºF, 3 minutes); seafood, crab, 6-log reduction C. botulinum (185ºF, 15 minutes) Hot hold / transport – ≥130ºF surface / center temperature, <1-log increase Clostridium perfringens Room temperature display (sushi, rice cakes, etc.) – <3-log increase B. cereus Cool food – hot to 120ºF in kitchen; 120 to 55ºF in 6 hours and continue to 41ºF no time limit, <3-log increase C. perfringens Cold hold – <3-log increase B. cereus; cook determines shelf life Ship food nationally – <3-log increase B. cereus until consumption


30

H0 Level

FSO

Critical Limit

Perf Crit

FDA FOOD CODE HOLDING / STORAGE RECOMMENDATIONS WITH HITM MODIFICATION 1.6 1.5

HITM - adapted FDA Food Code o y = 0.032*(temp C -(-2.924))* o (1-Exp (0.444 *(temp C - 52.553)))

1.4

0.5 0.59

1.2

0.69

1.1

0.83 1.0

1

1.2

0.9

Spoilage bacteria y= 0.016x-0.2969

0.8 0.7

1.6 2.0

Bacterial Pathogens y = 0.015x-0.4364

0.6 0.5

Time (hours)

[1/generation (h)]

1/2

1.3

0.4

2.8 4.0

0.4

6.3

0.3 0.2

11.1 25

0.1

100

0 0

20

40

60

80

100

120

140

o

Temperature ( F) spoilbac/Chart9

Temp. 10 (°F) 1 Generation Generations 30 293.5 123.8 days 35 45.7 19.3 days 40 18.2 7.5 days 41 15.6 6.5 days 45 9.5 4.0 days 50 5.9 2.4 days 55 4.0 1.7 days 60 2.9 1.2 days 70 1.69 16.9 hrs 80 1.11 11.1 hrs 90 0.79 7.9 hrs 100 0.59 5.9 hrs 110 0.47 4.7 hrs 115 0.46 4.6 hrs 120 0.56 5.6 hrs 125 3.1 31.0 hrs 382


31

WASHING AND BLANCHING FRUITS AND VEGETABLES (VEGETATIVE BACTERIA) HACCP Hazard: Raw fruits and vegetables are contaminated in the pores of the surface. Chemicals do not affect pathogens in the surface. Control: The bacteria must be removed by brush friction or water turbulence. The following reduces bacteria, parasites, and viruses about 2 log by dilution. 1. Trim. 2. Wash in turbulent water. Transfer to 2nd sink. 3. Rinse in turbulent water, 2nd sink. 4. Spin dry. Chemicals can be used in a 3rd sink, but have a limited effect, 1 log. Blanch fruit or vegetable in 160ºF water, 1 minute, for a 5-log reduction. Validation: Put E. coli on food and measure before and after treatment, using E. coli Petrifilm™. presentations: RENO2008: Jan08-Tue-writing rev 1/2/08 3:09 PM print 1/2/08

32

FOOD PASTEURIZATION HACCP (VEGETATIVE BACTERIA) Hazard: Pathogens contaminate raw meat, fish, and poultry. Control: Salmonella is the target pathogen. Reduce Salmonella 5 log / 7 log. (Assumes the food is contaminated with about 1,000 / gram, and must be reduced to 1 per 100 grams.) Validation: • Contaminate with non-pathogenic E. coli. Take sample before heating, <70ºF. • Take samples about 130ºF, 140ºF, and 150ºF. By 150ºF, there should be >5 log reduction.


33

DESTRUCTION OF SALMONELLA IN FOOD DEATH CONTROLS

Time and temperature Nutrients and acids Water activity

DESTRUCTION OF SALMONELLA SPP. IN FOOD Temp. °F (°C)

7D USDA 5D FDA 6.5D FDA Poultry Hamburger Roast beef with 12% (100,000:1) (3,160,000:1) fat

130 (54.4)

86 min.

112 min

---

135 (57.2)

27 min.

35 min.

---

140 (60.0)

8.7 min.

11.2 min.

35 min.

145 (62.8)

2.7 min.

3.5 min.

13.8 min.

150 (65.6)

52 sec.

67 sec.

4.9 min.

155 (68.3)

16 sec.

21 sec.

1.3 min.

160 (71.1)

5.2 sec.

6.7 sec.

26.9 sec.

165 (73.8)

Instant

Instant

<10 sec. 1326 1326


34

COMPARISON OF D-VALUES for Salmonella spp., Listeria monocytogenes, and Escherichia coli O157:H7 Temperature

Salmonella spp. z = 10ºF

L. monocytogenes z = 11.28ºF

E. coli O157:H7 z = 8.30ºF

(F)

(C)

1D)

1D

1D

130

54.4

17.28 min

21.95 min

26.75 min

135

57.2

5.47 min

7.91 min

6.68 min

140

60.0

1.73 min

2.85 min

1.67 min

145

62.8

32.79 sec

1.03 min

25.02 sec

150

65.6

10.37 sec

22.21 sec

6.25 sec

155

68.3

3.28 sec

8.00 sec

1.56 sec

160

71.1

1.04 sec

2.88 sec

0.39 sec

165

73.9

0.33 sec

1.04 sec

0.10 sec


35

RETAIL FOODSERVICE SYSTEM PROCESS IDENTIFICATION PROCESSES WITH SIGNIFICANT RISK; ABRREVIATED HACCP PLAN PREREQUISITES Processes with Hazard Significant Risk (biological, chemical, physical) Cook / RTE food B: Staphylococcus aureus on skin, handler prepares Streptococcus in throat, Shigella from for work feces on fingers C: None P: Jewelry Get equipment to B: Vegetative pathogens prepare food C: Leaching heavy metal P: Equipment parts Buy food to be: Eaten as B: All pathogens purchased C: All hazards P: All hazards

Raw, cook makes safe

B: Vegetative pathogens and spores C: All hazards P: All hazards Store refrigerated B: No significant increase food C: None P: None


Control B: Wash fecal pathogens off fingers. Don't cough on food. Don't touch skin. Cover cuts.

P: Not allowed. B: Wash, rinse, sanitize. C: Only stainless steel, wood, FDA plastic. P: Keep equipment repaired. B: Supplier exclusion. No cross-contamination, H0+ΣI
36

RETAIL FOODSERVICE SYSTEM PROCESS IDENTIFICATION (CONT'D)

FOOD PROCESS HACCP Processes with Significant Risk

Hazard (biological, chemical, physical)

Cut up raw food on cutting board

B: Cutting board and hands contaminated with pathogens from raw food C: Chemicals P: Hazards Weigh ingredients B: None C: Additives P: None Food to be served B: E. coli, Salmonella vegetative pathogens without cooking C: None P: None Cook B: Vegetative pathogens; cooking activates spores C: None P: None Hot hold B: Spores C: None P: None Cool B: Spores C: None P: None Mix cold B: Spores, vegetative pathogens ingredients, salad C: None and sandwiches, P: None or reheat Take-out B: Spores C: None P: None Cold hold B: Spores C: None P: None presentations: RENO2008: Jan08-Tue-writing rev 1/2/08 3:09 PM print 1/2/08

Control B: Wash, rinse, sanitize cutting board, hands, and utensils after contact with raw foods. C: Do not cross-contaminate. P: Remove physical hazards. C: Used at a safe level. B: Wash vegetables; ferment; acidify. B: Pasteurize. Reduce vegetative pathogens 5 log. Keep >130ºF for spore control. B: >130, spores can't germinate. B: Cool <14 hours; spores can't germinate. Time as control: 135 to 41°F, 4 hours, and throw away controls spores. If 41 to 70°F, 6 hours controls Lm. B: Mix <50ºF. Prevent vegetative pathogen crosscontamination. B: Control spores by eating in <6 hours if at room temperature or refrigerate. B: Control spores by keeping ≤41°F or, if raw fish, <38°F.

37

FOOD GROUPS HACCP PROCESS ANALYSIS

I

II

III

IV

V

HACCP Process Groups (USDA HACCP, 9 CFR 417) Prerequisite / GMPs working Not heat treated, not shelf stable (raw). Not PHF / no RPG: sprouts; raw meat, fish; sushi, sashimi; eggs, raw fruits and vegetables

Control

Grown safe, with H0 that meets FSO. May require Temperature Control for Quality. Grown safe, made safe by supplier, Not heat treated, with inhibitors to make shelf stable. Water activity: flour, corn meal, nuts, salt, sugar, sugar icing, with H0 that, with +ΣI-ΣR (5-log honey, spices and herbs, oil, lard; salted, dried fish, fresh pasta Salmonella), meets FSO. Fermentation: pepperoni, salami; olives; dairy (cheese, yogurt, Does not require TCS because of sour cream / milk / crème fraîche); bread; sauerkraut; kimchee; product aw, pH, or additives. beer, wine Acidified: salad dressing; cole slaw; salsa; condiments Fully cooked, not shelf stable. hot or cooled, refrigerated Pasteurized (5-log to 7-log ready-to-eat food; meat, fish, poultry; fruits, vegetables, dairy, Salmonella) so that +ΣI-ΣR meets pastry filling, pudding FSO. Requires TCS. Fully cooked, with inhibitors to make shelf stable. marinara Pasteurized (5-log to 7-log sauce; fruit pie fillings; cake icing, bread and pastry, dry Salmonella) so that +ΣI-ΣR meets cereals, dry pasta, smoked fish; packaged, low-pH fruits and FSO. vegetables Does not require TCS because of product aw, pH, or additives. Commercially sterile, shelf stable. "packaged" meat, fish, Sterilized, Clostridium botulinum poultry, fruits, vegetables, dairy / UHT milk spores reduced 9 log to 12 log. Does not require TCS.

PHF=Potentially Hazardous Food; RPG-Rapid and Progressive Growth; UHT=Ultra High Temperature; Ho=Starting Hazard; FSO=Food Safety Objective; Σ=summary; I=Increase; R=Reduction; TCS=Temperature Control for Safety; aw=water activity


38

Shelf life <14 days (bact. spoilage)

>2 years, 70ºF (chem. spoilage)

41 to 135ºF, ≤4 hours or Cold 41ºF, 14-90 days >5 years

>5 years

RETAIL PROCESS HACCP BASED ON FIVE USDA HACCP PROCESSES Transport, Hold, Serve No B,C,P crosscontamination.

N/A

Customer Consumption Raw food spoils safe. No B,C,P crosscontamination.

CCP. 5-log Salmonella kill with acid if eggs added or pH <4.2 or aw <0.92 or combination.

No hazard.

No hazard.

No hazard.

CCP. Cooking gives a 5-log to 7-log Salmonella kill; spores survive. No inhibitors. CCP. Cooking gives a 5-log to 7-log Salmonella kill. pH, aw , and chemical inhibitors prevent spore outgrowth. CCP. Product receives a 9-log to 12-log Clostridium botulinum reduction.

CCP. >130ºF.

CCP. <6 hours, 120 to 55ºF.

CCP. <40ºF or <3 log growth of vegetative pathogens before consumption.

No hazard.

No hazard.

No hazard.

No hazard.

No hazard.

No hazard.

Process

Purchase

Receive / Store

I. Not heat treated, not shelf stable Raw mushrooms, green onions, salad greens, fruit, fruit juice, fresh fruit and vegetable salads, fish, beef, pork, shellfish, eggs

CCP. Farmer has HACCP and guarantees safe levels of hazards on food. CCP. Farmer / supplier has HACCP and guarantees safe levels of hazards on food. <103 Salmonella. Chemicals at tolerable levels.

No B,C,P crosscontamination

Remove hard foreign objects. Wash fruits and vegetables, 2 log. No cross-contamination.

No B,C,P crosscontamination.

No B,C,P crosscontamination

Remove hard foreign objects. Wash fruits and vegetables, 2 log. No cross-contamination.

No C,P crosscontamination.

Remove hard foreign objects.

<103 Salmonella. Chemicals at tolerable levels.



<1 Clostridium botulinum / gram Chemicals at tolerable levels.



II. Not heat treated, with inhibitors to make shelf stable Combine flour, nuts, salt, sugar, vinegar, eggs, milk, etc. to make foods such as butter with honey, herbs, acid, salad dressing, pickles, olives, kimchee, wine. III. Fully cooked*, not shelf stable Ready-to-eat meat, fish, poultry, butter, cheese, ice cream, salads with cooked safe ingredients IV. Fully cooked*, with inhibitors to make shelf stable Smoked, salted, canned meat, fish, poultry; canned fruit; jam, jelly, syrup, processed cheese, acidic sauces (BBQ sauce, catsup), acidic beverages, bread, bagels, cake, cookies, dry cereals, taco shells) V. Commercially sterile**, shelf stable Hermetically / anaerobically packaged food (vegetables, beans, meat, poultry, fish, soup, dairy products)

Pre-Prep

Preparation

Cool

B,C,P = biological, chemical, and physical Not shelf stable = pathogenic vegetative cells can grow, and spores can outgrow *Fully cooked = 5-log to 7-log Salmonella treatment or Food Safety Objective (FSO) of <1 Salmonella / 25 grams **Commercially sterile = 9-log to 12log Clostridium botulinum treatment


39

CHILLED FOOD COOKING HACCP

SHELF-STABLE RECIPES WITH pH AND Aw CONTROL 1. Ingredients with enough acid (acetic, citric, lactic) to get equilibrium pH of ≤4.2, (Bacillus cereus spore control) OR Ingredients with enough salt or sugar to get a water activity of <0.92 (Bacillus cereus spore control). 2. Cook / mix. Add mold and yeast inhibitors (e.g., benzoate, sorbate). Add thickeners. 3. If there are solid ingredients (e.g., meatballs, eggs), add them and package. Wait 1 to 3 days. The protein in the added ingredient will tend to combine with some of the acid, and the pH will rise. Verify that the final pH at equilibrium is <4.3 for Bacillus cereus or <4.6 for Clostridium botulinum. Verify aw, if that is being used for control.


40

READY-TO-EAT CHILLED FOOD PROCESSES 1. ASSEMBLE-COOK-PACKAGE HOT-CHILL Pre-prep assembleĆook pasteurize´Pump, package hot, MAP, vacuum, airĆhill Stews, sauces, soups, sandwich spreads, fruit pie fillings, pudding 2. ASSEMBLE-SEAR-PACKAGE-COOK-CHILL a. Pre-prep assemble´Sear´Vacuum packageĆook pasteurizeĆhill Sous vide, rolls and roasts, canned crab and ham b. Pre-prep assemble´Package (pan / tray), MAP, vacuum, airĆook pasteurizeĆhill Casseroles (meat, pasta, vegetable, sauce combination) pates, meat, fruit, and cream pies, quiches 3. COOK-CHILL-ASSEMBLE-PACKAGE a. Pre-prepĆook pasteurizeĆhillÁssemble whole´Package, MAP, vacuum, air Roast or fried chicken, other roasts, uncured sausage, bread b. Pre-prepĆook pasteurizeĆhill´Slice / dice assemble´Package, MAP, vacuum, air Uncured luncheon meat, diced meat c. Pre-prepĆook pasteurizeĆhillÁssemble (pan / dish / tray)´Package, MAP, vacuum, air Meat and pasta, dinners, meat and sauces, sandwiches and pizza, milk d. Pre-prepĆook pasteurize´Partial chill??´Fill in doughĆhill´Package, MAP, vacuum, air Meat pies, quiches, patties, pates, filled pastries 4. ASSEMBLE WITH COOKED AND RAW INGREDIENTS-PACKAGE a. Pre-prepÁssemble cold raw and cold pasteurized ingredients´Package, MAP, vacuum, air Chef's salads, fruit salads, leafy salads, chicken salads / cold casseroles, sandwiches, pizza with raw ingredients b. Pre-prepÁssemble cold raw / cold pasteurized and hot (liquid) ingredients´Package, MAP, vacuum, airĆhill / gel Uncured jellied meats, gelled fruits Farber, J.M. and Dodds, K.L., eds. 1995. Principles of Modified-Atmosphere and Sous Vide Product Packaging. Technomic Publishing Co. Inc. Lancaster. p. 353.


41

HACCP FLOWS-CHILLED FOOD PROCESSES


42

FLOW CHART: FIVE PROCESS GROUPS Prerequisite processes are in place.

Process flow with controls Tasks Steps or a menu item if only one CCP

• •

Hazard and Risk Analysis B,C,P hazard identification Tolerable level / size Risk assessment Severity (cost) Probable hazard levels / size Probable occurrence) Acceptable risk Significant risk (Basis) Yes; next step Yes

Control(s) Critical limit, FMEA and process control(s) to reduce / prevent / eliminate a significant risk to an ALOP • Validation and reference • Expected process deviations • Process criterion to achieve a Cpk>1 within expected process deviations •

Monitoring / Self-check Who, how, when, what to measure process variation and keep inside the critical limit(s) Where is it recorded?

Is this step the best CCP? No; next step Yes

Get ingredients Supplier Supplier Unsafe; Safe TCS z I. Trim, wash Yes, TCS z II. Additives, ferment No TCS III. Pasteurize Yes TCS z IV. Pasteurize + Additives No TCS V. Sterilize No TCS Combine, Serve


43

Corrective Action (by HACCP Team) If deviation created a significant risk, what corrective action was taken?

Verification and Analysis for Process Improvement Who, how, when, what

QUALITY-ASSURED HACCP RECIPE PROCEDURES Recipe Name: Chicken Cacciatore Production style: Combination Written by: O. P. S. Date: 10/95 SA/QA by: J. Bell Date: 12/95 Gp. # I

Ingred. # 1 2 3 4 5 6 7 8 9 10

II

11

Portion size (vol./wt.): 1/4 (6 oz.) chicken + 3 oz. sauce Number of portions: 100 Final yield (AS):100 Final yield:

Ingredients and Specifications Onions, chopped (1/2" x 1") Mushrooms, cut (1/2 ", caps & stems) Peppers, green, cut (1/2" x 1") Garlic, chopped Tomatoes, canned, crushed ( 2 - #10 cans) Oil, vegetable Wine, Marsala or Madeira Oregano, crushed Salt Pepper Total Approx. gallons Chickens, whole (25 - 2¼ to 2½ lb.)

Preparation time: 2 hours Prepared by: S. P. Supervisor:

Edible Portion (EP) (weight or volume) 3.0 lb 1,360.00 g 3.0 lb 1,360.00 g 2.0 lb 907.2 g 6 Tbsp. 85.05 g 13.25 lb 6,010.00 g 1/4 cup 2 cups 2 tsp. 1 tsp. 1 tsp. 22.6 lb 2.5 gal. 62 lb

54.00 g 472.00 g 3.00 g 5.50 g 2.10 g 10,258.85 g

EP Weight % 13.26 13.26 8.84 0.53 58.58 0.53 4.60 0.03 0.05 0.02 100.00

As served (weight)

22.0 lb 40.0 lb

Preparation 1. Prepare sauce. Get chopped onions, mushrooms, green peppers and garlic (40°F) from refrigerator. Sauté the vegetables in vegetable oil for about 10 minutes. Add crushed tomatoes with juice, wine, and seasonings (72°F). Bring sauce to a simmering temperature (205°F, 10 min.). 1a. Hold sauce in bain marie. (165°F, 20 min.) 2. Prepare chicken. Get chicken quarters (40°F) from meat and poultry refrigerated storage area. Remove rib bones. (45°F, 10 min.) 3. CCP Place quarters, one layer deep in shallow roasting pans. Brown chicken by baking it in a convection oven at 350°F for 30 min. (>165°F, >15 sec.) 4. Remove pans of chicken from oven. (165°F, 15 min.) Pour off excess liquid. Save for chicken stock. 4a. CCP Cool liquid from 135 to <41ºF, <6 hours, <2 inches deep or <1-gallon container. 5. Cover the chicken quarters with sauce, 155°F, <10 min. (Final temperature 150ºF.) 6. Return the pans of chicken and sauce to convection oven at 300°F and continue baking until all parts of the chicken reach a temperature of 175°F (about 45 minutes). 7. Check temperature of chicken. If temperature is not 175°F, continue baking. 8. Cover chicken, 175ºF, transfer to 150°F hot holding unit and serve within <2 hours.

Verif.

Hold / Serve 9. Hold / serve chicken >150ºF, <2 hours. For each portion, use either 1/4 quarter white or dark meat. Chicken should be accompanied by 3 ounces of sauce (165ºF) (about 3 tablespoons). Leftovers 10. CCP Cool from 135 to <41°F in <6 hours, ≤2 inches deep or <1-gallon container. Ingredients that could produce possible allergic reactions: Tomatoes, wine Process step #

Start food ctr. temp., ºF

Thickest food dimension (in.)

Container size HxWxL (in.)


Cover Yes/No

Temp. on/ around food

End food ctr. temp., ºF 44

Process step time, hr./min.

CHICKEN CACCIATORE QA RECIPE FLOW Preparation 1. Prepare sauce. Get chopped onions, O mushrooms, green peppers, minced garlic. Sauté in oil. Add crushed tomatoes, juice, wine, and seasoning. Bring to a simmer.

1a. Hold in bain marie. D

Ti 205°F

Ti 40°F 2. O

To 205°F t 20 min. ↓ Get chicken quarters from refrigerator. Remove rib bones.

Ti 40°F 3. O

To 165°F

t 20 min.

To 45°F

t 10 min. ↓ CCP Place quarters, one layer deep in shallow roasting pan. Bake (brown) in convection oven at 350°F to >165ºF, >15 sec.

Ti 45°F 4. O

To >165°F t 30 min. ↓ Remove pan(s) of chicken from oven. Pour off excess liquid. Save for chicken stock.

4a. CCP Cool liquid from 135 to 41ºF in <6 hr., D <2 inches deep or <1-gallon container. (Save for chicken stock). Ti ≥135°F

Ti >165°F 5. O

To 155°F t 15 min. ↓ Cover chicken quarters with sauce.

Ti 155°F 6. O

t <10 min. ↓ Bake at 300°F in convection oven until chicken reaches a temperature of 175°F.

To <41°F

t < 6 hr.

To 150ºF

D =

Delay

I

=

Inspect

O =

Operate

S =

Store

T =

Transport

Ti =

Temp. in

Ti 175°F To 150°F t 5 min. Hold/Serve ↓ 9. Hold. Serve 1/4 chicken and 3 oz. sauce. D Use within <2 hr.

To =

Temp. out

t

Time to do the step

Ti 150°F To 150°F t <120 min. Leftovers ↓ 10. CCP Cool from 135 to <41°F, <6 hr., D ≤2 inches deep or <1-gallon container.

CCP = Critical Control Point

Ti 150°F 7. I 8. T

To 175°F t 45 min. ↓ Check. Is the temperature 175ºF? If not, continue to cook. ↓ Yes Cover and transfer to 150°F hot holding unit.

Ti 135ºF

To <41ºF

No

=

t <6 hr.


45

CHICKEN CACCIATORE HACCP PLAN Process Steps and Controls: GMPs and prerequisites are in place (Ti=temp. in; To=Temp. out; t=Time to do the step)

Preparation 1. Prepare sauce. Get chopped O onions, mushrooms, green peppers, minced garlic. Sauté in oil. Add crushed tomatoes, juice, wine and seasoning. Bring to a simmer. Ti 40°F To 205°F t 20 min. 1a. Hold sauce in bain marie. D Ti 205°F To 165°F t 20 min. 2. Get chicken quarters from O refrigerator. Remove rib bones.

Ti 40°F To 45°F t 10 min. 3. CCP Place quarters, one layer O deep in shallow roasting pan. Bake (brown) in convection oven at 350°F, >165ºF, >15 sec. Ti 45°F To>165°F t 30 min. 4. Remove pan(s) of chicken from O oven. Pour off excess liquid.

Save for chicken stock. Ti >165°F To 155°F t 15 min. 4a. CCP Cool liquid from

D 135 to 41ºF, <6 hr., <2 inches deep or <1-gallon container. (Save for chicken stock).

Ti ≥135°F To 41°F t<6 hr. 5. Cover chicken quarters with O sauce. Ti >155°F To 150°F t<10 min. 6. Bake at 300°F in convection O oven until chicken reaches a temperature of 175°F. Ti >150°F To 175°F t<45 min. 7. Check. Is the temperature I 175ºF? If not, continue to cook.

B, C, P, Potential Hazards and Risk Analysis

Control Critical Limit (CL) for each Hazard Control

B: Not significant. C: None. P: None.

Supplies are obtained from reputable sources; sauce has low pH and is heated sufficiently to destroy vegetative pathogens.

B: C: P: B: C: P:

B: Vegetative pathogens and spores C: None P: None

No pathogenic microbial growth in sauce at >130°F. Vegetative pathogens and spores are controlled by low temperature. Inspect to assure that all bones are removed Cooking temperature >165°F, >15 sec. assures a >7D salmonellae kill.


Temperature >130°F controls spores and kills vegetative cells.

B: Pathogenic spores C: None P: None

Cooling chicken stock from 135 to 41ºF, <6 hr., controls spore outgrowth.

B: C: P: B: C: P:

Not significant None. None. Not significant. None. None.

Temperature >130°F controls spores and kills vegetative cells. Temperature >130°F controls spores and kills vegetative cells.



Not significant. None. None. Not significant. None Not significant.


Monitoring & Record; (What, How, Frequency, Who)

Corrective Action & Record

Assigned worker takes lowest temperature of center of food in each lot and records on production sheet for each lot.

If temperature is not >165°F, continue to cook.

Supervisor initials the production log each shift.

Use clean, sanitized container and refrigerator that is validated for safe cooling

If refrigeration goes off, move stock to a functioning refrigeration unit. If cooling is not within FDA recommendations, throw it out.

Supervisor initials the production log each shift.

46

Verification & Record (Procedures and Frequency)

Process Steps and Controls: GMPs and prerequisites are in place (Ti=temp. in; To=Temp. out; t=Time to do the step)

B, C, P, Potential Hazards and Risk Analysis

Control Critical Limit (CL) for each Hazard Control

8. Cover and transfer to 150°F hot T holding unit. Ti 175°F To 150°F t 5 min. Hold/Serve 9. Hold. Serve 1/4 chicken and D 3 oz. sauce. Use within <2 hr. Ti 150°F To 150°F t <120 min. Leftovers





10. CCP Cool from 135 to D <41ºF, <6 hr., ≤2 inches deep or <1-gallon container.

B: Pathogenic spores. C: None P: None

Cooling to <41ºF in 6 hours assures safety. The presence of pathogenic microorganisms from cross-contaminated products is controlled by GMPs and SSOPs.

Ti 135ºF To <41ºF t <6 hr.

Monitoring & Record; (What, How, Frequency, Who)

Corrective Action & Record

Assigned worker makes sure the food is at the proper depth to cool to <41ºF in 6 hours. This is recorded on production sheet for each lot.

If refrigerator goes off, transfer to a functioning refrigeration unit. If containers are the wrong size, get the correct size.

Verification & Record (Procedures and Frequency)

The production schedule will be initialed by a supervisor once a shift, prior to transfer to refrigerator. The supervisor will initial that the CCP has been met.

Approved (QC) __________________________________________________________ Date __________________________ Approved (Process Authority) _______________________________________________ Date __________________________


47

FOOD HOT HOLD HACCP (SPORE CONTROL) Hazard: • The surface of food with a center temperature of 140ºF in a steam table exposed to air with a relative humidity of 50% will be about 117ºF because of evaporative cooling. • Clostridium perfringens will grow <125ºF. • Heat lamps dry food. Control: Keep food covered; keep high humidity, >90%, above food; or cover food with something like a butter sauce or cheese. Validation: • Make a pan of instant mashed potatoes with cooked ground beef on the surface. • Measure temperature. Hold in a steam table for 4 hours. Measure Clostridium perfringens.


48

FOOD COOLING HACCP (SPORE CONTROL) Hazard: Clostridium botulinum, Bacillus cereus, and Clostridium perfringens spores will germinate and multiply if cooling is too slow between 125 and 80ºF. Control: • Cool fast enough between 120 and 80ºF to prevent outgrowth of spores <1 log. • Pre-cool room temperature. • Blast cooler 1,000 feet per minute air, 38ºF, 2-inch pan, 6 hours. • Ordinary refrigerator 50 feet per minute air, 2-inch pan, 15 hours. Validation: • Cook hamburger to 160ºF to pasteurize the food and activate the spore. Put in a test container. • Cool. Take a center sample before and after cooling. Determine if there is growth using Petrifilm™.


49

COOLING FOOD FROM 120 TO 55ºF IN 6 HOURS (USDA GUIDELINES) COMPARED TO FDA 6-HOUR COOLING RECOMMENDATION

o

68

USDA: 120 to 55 oF in 6 hours Cooling Rate = 8.75 hours per log10 temperature reduction

o

minus Air Temperature) F

Log10 (Temperature Difference (Food Center Temperature

COOLING TIMES AND TEMPERATURES Food Center Temperature ( F)

138 128 118 10 98 88 78

100

58

48 47 46 45 44

10

43 42

FDA: 135 to 41oF in 6 hours. Cooling Rate = 3.9 hours per log10 temperature reduction

41 40

1 0

2

4

6

8

10

12

14

39

16

USDA Cooling FDA 6-Hour 120 to 55ºF in 6 Cooling hours, followed by 135 to 41ºF cooling to 40ºF (38ºF Environment) (38ºF Environment) 0 135 0 120 1 94 1 101 2 70 2 86 3 55.8 3 75 4 48.0 4 66 5 43.5 5 60 6 41 6 55 7 51 8 48 9 45.5 10 43.9 11 42.5 12.6 41 14.16 40

Time (hours)

1342


50

FSMS WITH PROCESS PERFORMANCE STANDARDS 1. Management 7. Food HACCP processes Process Safety Objectives / performance standards INPUT Baseline hazards H0 Prerequisite Processes 2. Personnel Æ Double wash, nail brush 6-log reduction 3. Environment

Æ

4. Facilities

Æ

5. Equipment Æ Pest prevention; Food contact surface wash 5-log / 2-log reduction 6. Supplies Æ Food that the farmer grew / processor made safe; Prevent crosscontamination / allergen identification; Chemical control

Biological, Chemical, and Physical Hazards Controls: Prevent, Eliminate, Reduce + Σ Increase - Σ Reduction pathogen substance Physical hazards: remove, reduce <1/16 inch Fruits and vegetables: wash 2-log or surface blanch 5-log reduction Pasteurize (in package or not) 150ºF for 1 minute for 5-log Salmonella reduction Additives / dry shelf stable Sterilize 250ºF for 3 minutes for 12-log Clostridium botulinum reduction Hot hold >130ºF / 135ºF Cool <2-inch pan, <6-inch diameter pot, <1-log Clostridium perfringens multiplication Cold hold <41ºF, <1-log spore / vegetative cell multiplication Acidify, shelf stable pH <4.2 Salmonella, Bacillus cereus, <4.6 Clostridium botulinum Water activity, shelf stable <0.86 Staphylococcus aureus, <0.92 Bacillus cereus


51

Daily Operations Report

OUTPUT FSO / ALOP

Æ 8. Products and Services

Customer abuse: Eat before 1-log increase of spore / vegetative cell multiplication or refrigerate immediately Cook, package, store, serve later

AMC-HACCP FOOD SAFETY MANAGEMENT PLAN for ________________________ Log of changes to manual

Operations Description (Plan Review) Food safety assurance Description of the system and processes Menu HACCP Organization Environment Facilities Major equipment -Retail food safety management: Evidence of control -Description of the system and products -Cook control – Menu-product groups / Supplier control – Menu-product groups -Organization chart -Environment surrounding the facility -Facility plan -Major equipment items

AMC-HACCP Management Food safety policy Management responsibility Food safety management plan Evaluation of unit performance; management review Food safety improvement program The Person In Charge (PIC) Holding subordinates responsible HACCP team operations Coaching and skill development Setting the example Daily QA self-inspection HACCP team meeting, report, and corrective action Employee and customer suggestions Emergencies Power outage Water contamination Fire and natural disasters Choking Food security Management Human element – staff Human element – public Facility Operations

Food sabotage Regulatory / third-party audit HACCP reassessment Training -Daily operations report -Corrective action report -HACCP team monthly meeting report -Employee food HACCP training checklist / qualification

Prerequisite Processes Personal Hygiene Individual illness Cuts and abrasions Personal cleanliness Fingernails Hair restraint Jewelry and hard objects in pockets Handkerchiefs and facial tissues Chewing gum, smoking, and eating Hand washing Handling food, money, and dirty tableware Cleaning, Maintenance, and Pest Control Cleaning Cleaning plan Food sinks vs. hand and utility sinks Knowing that equipment is sanitized Food contact surface wiping cloths Sanitizing food contact surfaces 3-compartment sink operation Bussing tables Equipment cleaning Food waste cans Tableware Work station cleanliness Chemicals and MSDS Maintenance Maintenance plan Cooler-freezer temperatures Pest Control Pest control plan - Cleaning and sanitizing schedule - Chemicals list and material safety data sheets - Equipment list / preventive maintenance schedule Supplies Supplier and ingredient certification Inspection of incoming products Substandard products


Receiving food Proper storage procedures: ambient, frozen, refrigerated Prevent food contamination: physical, chemical, biological Chemicals separation -Ingredient and supplier qualification list

Food Process HACCP Documentation Recipe process HACCP groups Food pre-preparation hazard and control rules Prevent cross-contamination Chemicals separation Chemical additives Allergies and adverse food reactions Food thawing Food washing Serving raw foods Physical hazards / hard foreign objects Ingredient control Allergenic ingredient control Separate raw and cooked food preparation equipment Food preparation hazard and control rules Food product thermometers Salad bar Pasteurization and quality temperatures Food transport, holding, and serving hazard and control rules Hot holding Food serving temperatures Food removed from temperature control Serving, packaging, transporting Cooling food Cold holding Reheating for hot holding Table condiments Communicating food safety Carry-out, catering, and banquets hazard and control rules - Quality assurance recipe procedures - Five retail USDA-based food process flows - HACCP flow diagram - HACCP plan

52

MENU ITEM HACCP PLAN Menu Item Baked potato, raw

Storage Dry storage, RT, 10 days.

Charleston chicken, raw Chicken wings (buffalo wings), supplier pasteurized

Hold in FD, 0ºF / 24 hrs.

Chicken fried steak, raw Hamburger (Junior Burger, 3 oz.), raw

Hashed browns, aw control, supplier pasteurized Boca Burger, supplier pasteurized Steak, sirloin / steak T-bone, raw Eggs, pasteurized liquid, supplier pasteurized Eggs, fried, raw Eggs, hard boiled, raw Oatmeal, aw control, supplier pasteurized

Portion 9 chicken wings in food storage bag. Thaw in refrig. 24 hrs. / Hold 48 hrs. in WR <40ºF (clock label). Hold in FD, 0ºF / 24 hrs. Frozen, wrapped 24 hrs. / FD.

Unopened (dry storage, RT). Rehydrated shelf life 24 hrs. including 20 minutes rehydration <40ºF (clock label). Hold 24 hrs. FD, 0ºF. Frozen / thaw 24 hrs. refrig. Hold 48 hrs. / RD <40ºF (clock label). After opening 24 hrs. / WR <40ºF (clock label).

Preparation Double wash. Wrap in aluminum foil. Bake at 400ºF until soft (190ºF) >160ºF, 15 sec. CCP. Deep fry (350ºF) to >165ºF, 15 sec. CCP. Deep fry (350ºF) to >165ºF, 15 sec. CCP.

Hold / Serve Hold >160ºF, <1 hr. / WD. CCP.

Leftovers None

Serve immediately.

None

Serve immediately.

None

Cook to order. Deep fry (350ºF) to >160ºF, 15 sec. CCP. Cook to order, from frozen >160ºF, 15 sec. CCP. (Temperature measurement must assure destruction of E. coli.) (Add seasoning.) Cook to order >160ºF, 15 sec.

Serve immediately.

None

Serve immediately.

None

Serve immediately.

None

Cook to order >160ºF, 15 sec.

Serve immediately.

None

Cook to order >145ºF, CCP unless customer requests otherwise.

Serve immediately.

None

Cook to order (scrambled eggs, omelets) to >150ºF, 15 sec.

Serve immediately.

None

Serve immediately.

None

24 hrs. refrig. <40ºF.

Discard

Service immediately. ST = 4 hrs., >160ºF

Discard

Refrigerated shell eggs (<40ºF). Cook to 145ºF, 15 sec., unless customer requests otherwise. CCP. Refrigerated shell eggs (40ºF). Cook for 10 minutes, >150ºF, 15 sec. Pour ice over eggs to cool. CCP. RT storage Mix pack with hot water (>190ºF) or: Kettle, add oatmeal to boiling water, simmer 8-10 minutes <160ºF, 15 sec.


53

Menu Item Mashed potatoes, aw control, supplier pasteurized Celery, raw Lettuce, iceberg, raw

Mushrooms, raw, supplier vegetative pathogen safe Tomatoes, raw Parsley

Roast beef, supplier pasteurized Cheddar cheese (shred), aw control, supplier pasteurized Mayonnaise, pH control, supplier pasteurized

Storage RT storage

5 days refrig. <40ºF (cover label, clock label). 5 days refrig. <40ºF (cover label, clock label).

3 days refrig. <40ºF (cover label, clock label) 5 days refrig. <40ºF (cover label, clock label). 7 days refrig. <40ºF (cover label, clock label). Stored frozen, thaw 24 hrs. / WR (clock label). 5 lb. plastic bags 3 mths. / WR <40ºF. 1-gal. plastic jar, unopened (store room) = expiration date

Iced tea, freshly Dry storage, RT brewed, supplier safe


Preparation Mix 2 qts. boiling water (212ºF), 2 oz. Liquid Margarine and 1 bag potato mix >160ºF, 15 sec. Clean and trim. Double wash. CCP. Cut or dice <40ºF. Clean, core, remove brown leaves. Double wash. CCP. Quarter. Separate leaves. Remove excess water. Store in plastic container <40ºF. Double wash. Remove stems. Slice <50ºF.

Hold / Serve Service immediately. ST = 4 hrs., >160ºF

Leftovers Discard

<40ºF, 24 hrs.

Discard

<40ºF, 24 hrs.

Discard

<40ºF, 24 hrs.

Discard

8 hrs. / CT <40ºF.

Discard

Washed, prepped 24 hrs. / CT <40ºF.

Discard

48 hrs. / RD <40ºF.

Discard

Use as directed.

Portioned 72 hrs. WR 24 hrs. / RD <40ºF.

Discard

Use as directed.

Open refrig. = 30 days, Discard not to exceed expiration date. WR <40ºF. 8 hrs. Discard

Double wash. CCP. Slice. stack slices in 4-inch insert pan. Inspect parsley, remove brown and yellow leaves. Double wash. CCP. Trim parsley to 1-to-1-1/2-inch stems. Use in sandwiches.

Prepare as directed. Brewing assures pasteurization.

54

STANDARDIZED MONITORING What to Measure Food temperature in cold holding (delivery, receiving, refrigerator) Cooked, pasteurized food Hot hold display Cooling

Cold hold display Refrigerator air temperature Oven temperature Oven humidity Fryer Food pH Food aw Surface safety


How to Measure Measure 1/8 to 1/4 inch below the top surface.

Measure temperature of center of thickest food item. Measure 1/8 to 1/4 inch below the top surface. Push through the thickest part of the food to find the warmest temperature. Measure 1/8 to 1/4 inch below the top surface Measure cup of salt, 8 oz., on the center shelf for >1 hour to stabilize. Measure cup of salt, 8 oz., on the center shelf for >1 hour to stabilize. Use a thermocouple in a cotton wick in water with air circulation. Using a tip-sensitive thermometer, measure oil temperature for 3 cycles and take the average. At 20ºC, measure pH with a strip or meter. Food can be diluted by 30% with distilled water, if needed. Use a Decagon aw meter or equivalent. Using Petrifilm™, do a contact plate or swab and look for <100 colonies per 8 square inches.

55

EMPLOYEE FOOD HACCP TRAINING CHECKLIST Critical Control Points

Demonstrated Correct Performance

Evaluation Date __________

Prerequisites Personal hygiene If I have vomiting or diarrhea, I will tell the PIC. I will double wash my fingertips when coming from an "unknown location" such as the toilet. When handling raw meat / fish / poultry, I will decontaminate my hands and food contact surface before touching RTE food. I do not touch my skin, face, or hair when working with food. Immediately after glove use, I remove the gloves and wash my hands. Receiving When receiving food / opening food, any food that is damaged or spoiled will be returned to the supplier / discarded. Refrigerate food 41°F. Storage I store raw food on the bottom shelves in the refrigerator and RTE food above the raw food, <41°F. I store chemicals completely separate from food. Equipment I assure that my equipment is clean before I use it. I assure that my equipment is working correctly and calibrated before I begin food preparation. Food process hazard controls I double wash raw fruits and vegetables before using in menu items. During pre-preparation, I remove physical hazards from food. During preparation, I consider if any ingredient in a recipe is an allergen and if so, remember it so that customer questions can be accurately answered. If in doubt, I refer allergen questions to the kitchen manager. I cook foods for pasteurization to: a. Solid steaks, chops, fish: 145ºF center temperature, 15 seconds b. Ground meat, fish: 155ºF, 15 seconds c. Poultry: 165ºF, 15 seconds OR: as ordered by the individual customer. I hold hot food >135ºF or <4 hours if time is used as a control. I cool panned food ≤2 inches deep or liquids in ≤1-gallon container. When making a cold combination such as salads, I pre-cool ingredients to <50ºF before mixing and avoid cross-contamination from Staphylococcus aureus on hands. I cold hold RTE food at 41ºF food temperature, <7 days; it is labeled. I do not add leftovers to a fresh food. I reheat food to 165ºF for 15 seconds in <2 hours. Cleaning responsibility (see over) On ___________, I trained ________________________ to know the above food safety information, and I verified that he/she could apply it in his/her work. _____________________________________ Trainer

___________________ Date


56

MANAGEMENT AND EMPLOYEES CAN DEMONSTRATE WHY THE FOOD IS SAFE Management

Knows hazards; assigns controls; assigns a coach and trains food handlers to do policies, procedures, and standards / SSOPs; takes corrective action; audits to improve

Prerequisite process Personnel Environment and Facilities Equipment Supplies

Wash fecal pathogens off fingertips, 6 log10 reduction; personal hygiene Clean; no pests Food contact surfaces: rinse, wash, rinse, sanitize, 5 log10 reduction Supplier makes safe Cook makes safe Fully cooked, preserved Raw

Food HACCP process

Law

HACCP

Receive, store

<41ºF

Raw food spoils safe Cooked, refrigerated food <50ºF, <3 log10 increase of Bacillus cereus

Pre-preparation

Wash fruits and vegetables

Friction wash fruits and vegetables, 2 log10 reduction; dilute bacteria or 5 log10 reduction surface blanch

Pasteurize

155ºF, 15 seconds: meat, fish 165ºF, 15 seconds: poultry

5 log10 reduction Salmonella Tip-sensitive thermometer

Hot hold / transport

>135ºF

>130ºF, <1 log10 increase Clostridium perfringens

Serve

>135ºF

>130ºF (150 to 170ºF quality)

Cool

135 to 41ºF, 6 hours

120 to 41ºF, 14 hours (2-inch pan, 1-gallon pot) <1 log10 increase Clostridium perfringens

Cold hold, pasteurized food

41ºF, 7 days

<50ºF, <3 log10 increase of Bacillus cereus (>30 days)

Reheat

41 to 165ºF, <2 hours

None; process must prevent toxin


57

EXCELENT HACCP

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