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 1

THE UNIT AS A FOOD PROCESS SYSTEM


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

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 OBSERVATION CORR. ACT. 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)


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


HACCP-TQM RETAIL FOOD

Food market

Restaurant

Management Continuous HACCP Improve

INPUT, Baseline Hazards

H0 Prerequisite Processes

FOOD HACCP PROCESS, + ΣI - ΣR

Reduce hazard to a TLR / ALOP*

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 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 Leftovers

TLR = Tolerable Level of Risk ALOP = Appropriate Level Of Protection


SYSTEM

Home

ment

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

Daily Operations Report

FSO = Food Safety Objective

RETAIL FOOD BIOLOGICAL HAZARDS

Vegetative. cells (Reduce)

Spores (Prevent

Germination) Parasites (Reduce)

Viruses (Reduce)

Biological Toxins

(Prevent)

Seafood toxins

(Prevent) 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

Bacillus cereus and other Bacillus spp.

Clostridium botulinum

Clostridium perfringens

Clostridium difficile

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

Staphylococcus aureus

Bacillus cereus Clostridium

botulinum

Scombroid


RETAIL FOOD CHEMICAL HAZARDS (Prevent / Eliminate)

Biogenic Amines, Toxins

Toxins & Natural Chemicals, Fungal &

Mushroom Toxins

Allergens and

IntoleranceOther Natural Toxins Residues Prions

Histamine Ciguatera Paralytic shellfish

poison Neurotoxic shellfish

poison Amnesic shellfish

poison Tyramine Serotonin Catecholamine

neurotransmitters Tryptamine

Lead Mercury Radionucleides

Milk Eggs Wheat Peanuts Soy Tree nuts Fish Crustacean

shellfish

Pyrrolizidine alkaloids Phytohaemagglutinin

(Red kidney bean poisoning)

Grayanotoxin (Honey intoxication), and others

Pesticides, herbicides, hormones, antibiotics

nCJD

RETAIL FOOD PHYSICAL HAZARDS (Reduce)

Broken Teeth Choking Cuts in Mouth Burns Bones Rocks Metal Twist ties / staples Pits / seeds

Plastic Wrap Large, insufficiently

chewed pieces of food

Glass Temperature of foods above 170ºF (77ºC)


TOXIC COMPOUNDS IN FOOD

Mycotoxins in grain Cooking does not eliminate. Kidney beans Must be boiled 10 minutes to reduce phytohemagglutinin to a

safe level. Soybeans Must be heated thoroughly to reduce heat-labile protease

inhibitors. Raw egg whites Conalbumin and avidin can impair metabolism. Mushrooms Can cause cancer in mice. Potatoes Solanine and chaconine are heat stable. Spinach, rhubarb Oxalates inhibit calcium absorption. Taro Trypsin inhibitors destroyed by heat. Parsnips Carcinogenic and mutagenic psoralens not destroyed by heat. Flavonoids Can inhibit enzyme systems and respiration. Alfalfa sprouts 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.


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

Raw Product Contamination

(H0)

Process Performance Criteria (ΣR)

Food Safety Objective (FSO)

MICROBIOLOGICAL (Reduce) INFECTIVE Vegetative pathogens - infection

Salmonella spp. / E. coli O157:H7 (food) 103 cfu/g 10-5 cfu/g - reduce 10-2 cfu/g or 1cfu per 100 g Shigella spp. (feces) (human) 106 cfu/g 10-6 cfu/g - reduce 10 cfu/g or 1cfu

Parasites Cryptosporidium parvum (food) 1 cyst prevent / reduce undetectable Toxoplasma gondii (food) 1 cyst prevent / reduce undetectable Trichinella spiralis (food) 1-500 larvae prevent / reduce undetectable

Viruses Hepatitis A (human) >10 virus / g prevent / reduce undetectable Norovirus (human) >100 virus / g prevent / reduce undetectable

TOXIN PRODUCING Staphylococcus aureus (exotoxin) (human) 103 cfu/g <103 cfu/g increase <106 cfu/g (toxin dose: <1 microgram) SPORES Clostridium botulinum (exotoxin) (food) 100 spores / g <103 cfu/g increase <103 cfu/g (toxin dose: ≤2 nanograms) Bacillus cereus (exotoxin, enterotoxin) (food) 102 spores / g <103 cfu/g increase <105 cfu/g (toxin dose: unknown) Clostridium perfringens (enterotoxin) (food) 102 spores / g <103 cfu/g increase <105 cfu/g (toxin dose: unknown) CHEMICAL (Prevent / eliminate) Sulfites Variable none added <10 ppm Nitrates Variable <500 ppm added <500 ppm Nitrites Variable <200 ppm added <200 ppm Monosodium glutamate Variable ≤0.5 g / serving added <3.0 g / meal Aflatoxins (from mold) <20 ppb no increase <20 ppb Histamine (from fish, cheese) <20 ppm no increase <20 ppm PHYSICAL (Prevent / eliminate) Hard foreign objects (broken tooth) >1/16 inch diameter prevent / remove undetectable Choking >1/4 inch diameter cut ≤1/4 inch <1/4 inch

* cfu = colony forming units


VEGETATIVE BACTERIAL PATHOGENS (5-log / 6.5-log Pasteurization or 2-log Wash)

Bacteria

Source

Min.

temp. (°F)

Max. temp. (°F)

Min. pH

Max. pH

Min aw

Time 1-log reduction at 140°F (minutes)

Toxin

Destruction

Aeromonas hydrophila Feces / food 29.3 111 4.0 7.2 - 0.02 m. n/a Listeria monocytogenes Feces / food 29.3 113 4.4 9.4 .92 3.8 m. n/a Yersinia enterocolitica Feces / food 29.3 111 4.2 10 .945 1.6 m. n/a Salmonella spp. Feces / food 41.4 115.2 4.2 8.0 .94 1.7 m. n/a Shigella spp. Feces / food /

water 43 116.8 4.8 9.3 .96 1.7 m. n/a

Escherichia coli O157:H7

Feces / food / water

44.6 114 4.0 9.0 .95 1.7 m. n/a

Vibrio cholerae Feces / food / water

50 109.4 5.0 10 .97 D120 =8.15 m. n/a

Vibrio parahaemolyticus Seafood / water 41 111 4.8 11 .94 D120 =0.82 m. n/a Vibrio vulnificus Seafood / water 46.4 109.4 5.0 10 .96 D122 =0.66 m. n/a Campylobacter jejuni Feces / food 86 113 4.9 9.3 .987 0.25 m. n/a

Staphylococcus aureus

growth toxin production

Nasal cavity, skin, infected cuts, boils, wounds

44.6 50.0

122 118

4.0 4.5

10 9.8

.83 .86

3 m.

68.6 minutes at

210°F


SPORE-FORMING BACTERIAL PATHOGENS - VEGETATIVE STATE

Bacteria

Source

Min.

temp. (°F)

Max. temp. (°F)

Min. pH

Max. pH

Min aw

Time for veg. cell

destruction at 140°F (minutes)

D-value (°F)

Spores

Toxin

Destruction

Clostridium perfringens

Soil, feces, sewage, water, dust

50 125 5.5 9.0 .93 3.5 m.

D210°F = 31.4 min. Beef Gravy (varies with type)

n/a

Bacillus cereus Soil, dust, grains, cereals

39.2

122

4.3

9.3

.92

1 m.

D212°F = 3.1 min. Skim milk

D212°F = 22 to 36 min. in rice

D132.8°F = 5 min for diarrheal illness D250°F = 90 min for emetic illness

Clostridium botulinum, type A, and proteolytic B and F

Soil 50

118.4

4.6

9.0

.935

Not available

D250°F = 0.23 to 0.3 min.

D174°F = 20 min. D185°F = 5 min.

Clostridium botulinum, type E, and non-proteolytic B and F

Water, sludge near bodies of water

37.9

113

5.0

9.0

.97

Not available

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

(same as above)


FOOD PROCESS HAZARD ANALYSIS HAZARD ANALYSIS

Infective vegetative bacteria, viruses, and parasites found in meat, poultry, milk,

vegetables, fruit, etc.

Chemicals, poisons, poisonous plants found in meat, fish, vegetables, casseroles,

and sauces Spores found in meat, milk, vegetables,

starches, cereals, and sauces

Purchasing (H0) Illness Dose (FSO*) Biological Toxins Illness Dose (FSO*) Illness Dose (FSO) Receiving-Storage Salmonella spp. 4 to 105 CFU Staphylococcal toxin 105 to 106 CFU/g Clostridium perfringens 106 CFU Vibrio spp. 103 to 1010 CFU (for toxin amount) Clostridium botulinum 103 CFU/g Campylobacter jejuni 400 to 500 CFU Botulinal toxin 103 CFU/g (for toxin hazard) Shigella spp. 10 to 100 CFU Scombroid toxin (histamine) >50 mg/100g Bacillus cereus 105 - 1011 CFU E. coli O157:H7 10 to 100 CFU Fish Poisons E. coli (enterotoxigenic) 106 to 1010 CFU Ciguatera poisoning >1 mg. toxin (for toxin and diarrhea Listeria monocytogenes 100 to 1000 CFU Paralytic shellfish poisoning >80 µg/100g hazard) Hepatitis A, norovirus, <10 Chemicals Parasites, tapeworms, <10 Monosodium glutamate >0.5% (Amt. in

food)

round worms, flukes Sulfites >10 ppm (Amt. in food) Nitrate and nitrites >200 ppm Spores are not a hazard until the process (Amt. in food) allows the spores to germinate and multiply PROCESS CONTROL

Cold handling Cook – hot Cold handling Cook – hot Cold handling Cook – hot Preparation Hazardous Hazardous No hazard <6 hours to ≥130ºF

Thaw 30 to 115ºF veg. path. mult. Competitive Spores activated but Cut Increases hazard microorganisms then, killed above

Wash Washing fruits and vegetables and time 130°F prevent reduces hazards significant increase.

Cook Pasteurize, 5-log reduction. Veg.

path. destroyed.Post-cook process 30 to 115ºF veg. path. mult. Cool. Only spore Hazardous Hazardous No hazard Hot hold >130ºF, no

increases hazard hazard; hazard veg. path. Cooling <6 hours, 120 destroyed to 55ºF – no hazard

Leftovers 30 to 115ºF veg. path. mult. <40ºF – no veg. Hazardous Hazardous No hazard <41ºF – no hazard Reheat not required for increases hazard path. hazard safety Prevent cross-contamination Prevent cross-

contamination

*FSO = Food Safety Objective


RETAIL HACCP PROCESS PERFORMANCE CRITERIA PREREQUISITE PROCESSES HACCP

Risk Proc System Processes H0 + ΣI - ΣR = FSO / ALOP

Critical Process Hazard Name Sev Det Freq H0

Level FSO Critical Limit Perf Crit

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


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 non-

pathogenic E. coli 2. Double fingertip wash, 6 log reduction 3. Petrifilm™ recovery E. coli <10 total


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 post-package 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 16

FLOW CHART OF LISTERIA CONTROL IN READY-TO-EAT FOOD PRODUCTION ROOM

FSIS DIRECTIVE 10,240.3

Day 1 1st 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.

Day 2

Day 3

Day 4 Negative Day 1 FCS sample,

Listeria spp.: Continue to operate.

Positive Day 1 FCS sample, Listeria spp.: Clean, sanitize.

Take 2 FCS samples for Listeria spp.

Produce product.

t

Day 5

Day 6

Day 7 Negative Listeria spp. Day 4

FCS: Release Day 4, 5, 6 product. Continue to operate.

Positive Listeria spp. Day 4 FCS, destroy product; best corrective action.

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)

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


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


FDA VS. HACCP PROCESS CONTROL STANDARDS Process Step FDA Performance Standard HACCP Performance Standard / Criterion

Receiving, storage, pre-preparation

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.

Preparation Fruit and vegetable

washing None. 2D wash E. coli reduction; 5D surface blanch E. coli reduction.

Pasteurization Meat, fish, fruits,

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

5D Salmonella (E. coli) reduction.

Poultry 165ºF, 15 sec. Hot hold, transport, serve, package

130ºF beef; 135ºF everything else. <1-log increase Clostridium perfringens, which begins to multiply ~125ºF, and at 105ºF, multiply every 15 min.

Cool 135 to 70ºF, 2 hr.; 70 to 41ºF, 4 hr. 120 to 55ºF, 6 hr. and continue to 40ºF (14.2 hr.) or <1-log increase of C. perfringens or Bacillus cereus (USDA).

Packaging ready-to-eat food

None. No detectable Listeria monocytogenes (<1 / 25 g) in ~3 samples every 3 months.

Cold hold 41ºF, 7 days. No standard. Until spoiled. <50ºF Clostridium botulinum control, <40ºF B. cereus control.

Shelf stable processed food

Vegetative cells <4.6 pH C. botulinum, <0.86 aw Staphylococcus aureus.

<4.2 pH Salmonella, <0.86 aw Staphylococcus aureus.

Spores <4.6 pH C. botulinum, <4.2 pH B. cereus, <0.92 aw B. cereus. Reheat 41 to 165ºF, 15 sec., 2 hr. No standard. Control not needed. Consumer abuse None. <3-log increase B. cereus.


SUPPLIER CONTROLS FOR SAFE PRODUCTS

CONTROL STABILIZEINGREDIENT Grown

Safe

HFO Sort,

Remove Wash Pasteurize

Sterilize Allergen (inform) Other Aw pH Acid /

Ferment Ref. /

Freeze

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


COOK CONTROLS FOR SAFE PRODUCTS CONTROL STABILIZE

INGREDIENT B,C,P Hazard HFO Sort,

Remove Wash Pasteurize Sterilize

Allergen (inform) Other Aw pH Acid /

Ferment Ref. /

Freeze 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


MENU ITEM ALLERGEN ANALYSIS

Big Eight Allergen Ingredients Food Intolerance Food

Product Peanuts Tree nuts

Milk and milk

by-products

Eggs Soy Wheat Fish Crustaceans and shellfish Sulfites MSG Other


PROCESS HURDLE TECHNOLOGY

Physical Hurdles Physicochemical 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

Water activity (aw) pH Redox potential (Eh) Salt (NaCl) Nitrite (NaNO2) Nitrate (NaNO3 or

KNO3) Carbon dioxide

(CO2) Oxygen (O2) Ozone Organic acids Ascorbic acid Sulphite or SO2 Smoking Phosphates

Glucono-δ-lactone (GDL)

Chelators Surface treatment

agents Ethanol Propylene glycol Maillard reaction

products (MRPs) Spices and herbs Lactoperoxidase Lysozyme Chlorine Chitosan


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 <l log growth Hemorrhagic E. coli <1 log growth Vibrio <1 log growth

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)

pH aw pH aw 4.4 0.990 4.8 1.0004.5 0.955 4.8 0.9884.6 0.935 4.9 0.9784.7 0.920 5.0 0.9734.8 0.913 5.1 0.9684.9 0.907 5.2 0.9645.0 0.902 5.3 0.9615.1 0.900 5.4 0.9585.2 0.898 5.5 0.955

5.6 0.953 5.7 0.951 5.8 0.950 5.9 0.949 6.0 0.948 6.1 0.947 6.2 0.946

7.0 0.946

Graphs adapted from: Evaluation and Definition of Potentially Hazardous Foods

Appendix C: Scientific Data Used to Develop Framework 1. Determination of pH and water activity limits for TCS foods http://www.cfsan.fda.gov/~comm/ift4-ac.html


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

pH PROCESS CONTROL

pH Description14.0 Very alkaline 10.0 Dishwashing chemicals, Milk of Magnesia, vegetative pathogen death 9.0 Upper growth limit for bacteria (>9.0 bacterial destruction) 8.5 City water 8.0 Alkaline

Egg white, hominy, devil's food cake 7.0 Neutral

Soaps, hand wash detergents Can cook in copper

6.0-7.6 Human saliva 6.8-4.6 Low acid

Most vegetables (corn, peas, potatoes, beans, lettuce), melons, meat, fish lobster, poultry, milk, cream, oatmeal, gravy, bread

6.8-6.5 Chlorine sanitizer 100% effective <5.0 Clostridium perfringens and Clostridium botulinum type E stop growing <4.6 Acid

Most fruits (apples, oranges, grapes, berries, pineapple, tomatoes), Jell-O Clostridium botulinum types A and proteolytic B growth is stopped

<4.5 Staphylococcus aureus toxin production stopped <4.2-4.0 Bacillus cereus, Salmonella, Escherichia coli, and Listeria monocytogenes stopped

4.0 BBQ sauce, catsup, mayonnaise, mustard, hollandaise sauce, pickles, jams and jellies, pickled pig's feet, carbonated beverages

2.0-3.0 Lemons, limes, cranberry juice, vinegar 1.0-2.0 Very acid

Digestive, hydrochloric acid of the stomach


WATER ACTIVITY (aw) PROCESS CONTROL

Minimal aw required for Bacterial, Yeast, and Mold Growth Water activity Food

1.0 WaterNo restriction >0.98 Fresh meats, poultry, fish

Fresh fruits and vegetables Milk, canned fruits and vegetables.

Yersinia enterocolitica 0.975 Campylobacter spp. >0.97 Clostridium botulinum, type E 0.97

0.98 to 0.95 Cooked meat, fish and poultry, bread

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

0.95 to 0.91 Cured meat products, cheeses

Most bacteria 0.91–0.88 Most yeasts 0.88

0.91 to 0.87 Fermented sausages, syrups

Staphylococcus aureus 0.83 Toxin production 0.86

0.87 to 0.80 Fruit juice concentrates, sweetened condensed milk, flours, rice, dried vegetables (peas, beans)

Regular molds 0.80 0.80 to 0.75 Jams, marmalade Halophilic bacteria 0.75 Xerotolerant molds 0.71

0.75 to 0.65 Fudge, marshmallows, jelly, molasses

Xerophilic molds and osmophilic yeasts 0.62-0.60

0.65 to 0.60 Dried fruits, caramels, honey

No microbial proliferation (growth) 0.60 to 0.20 Dry pastas (vermicelli), spices, dry milk powder, dried egg powder, crackers


NON-HAZARDOUS-INGREDIENT PRODUCTS DO NOT REQUIRE PROCESSING BY COOK FOR SAFETY

Protein Dairy CHO, Starch, Sugar Fats, Oils Fruit, Veg. Herbs, Spices,

Condiments Funct. Addit. Beverages

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

Cheese, hard Cheese, soft Cottage

cheese Cheese cake Milk Condensed

milk Cream Ice cream bar Sour cream Whipped

topping Yogurt Flan Butter Evaporated

milk

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

Honey Mousse, pudding, Jello Flour Syrup Molasses

Oil Pan coating Shortening

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

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

sauce

Dry spices Fresh herbs and

spices Ginger root Pepper Salt Sugar Cornstarch

Coffee Tea Soda Alcoholic

beverages Water, ice

Cookies


HAZARDOUS INGREDIENTS DO REQUIRE PROCESSING BY COOK FOR SAFETY

Protein Dairy CHO, Starch, Sugar Fats, Oils Fruit, Veg. Herbs, Spices,

Condiments Funct. Addit. Beverages

Meat Uncooked meats,

all (e.g., bacon) Fish Fish Scallops, shellfish Poultry Other Eggs

Raw milk and

any other unpasteurized dairy products

None

None

Fruits, fresh Berries Citrus fruit Coconut Fruit, non-citrus Melons, all Banana Vegetables, fresh Fresh vegetables Lettuce Spinach Non-protein-

bearing vegetables

Onion Peppers Potatoes Vegetables, low-

protein

None

None

None


RETAIL HACCP PROCESS PERFORMANCE CRITERIA FOOD PROCESS HACCP

Risk Proc System Processes H0 + ΣI - ΣR = FSO / ALOP

Critical Process Hazard Name Sev Det Freq H0

Level FSO Critical Limit Perf Crit

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


FDA FOOD CODE HOLDING / STORAGE RECOMMENDATIONS WITH HITM MODIFICATION

Temp. (°F) 1 Generation

10 Generations

30 293.5 123.8 days35 45.7 19.3 days40 18.2 7.5 days41 15.6 6.5 days45 9.5 4.0 days50 5.9 2.4 days55 4.0 1.7 days60 2.9 1.2 days70 1.69 16.9 hrs80 1.11 11.1 hrs90 0.79 7.9 hrs

100 0.59 5.9 hrs110 0.47 4.7 hrs115 0.46 4.6 hrs120 0.56 5.6 hrs

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

1.1

1.2

1.3

1.4

1.5

1.6

0 20 40 60 80 100 120 140

Temperature (oF)

[1/g

ener

atio

n (h

)]1/2

Bacterial Pathogensy = 0.015x-0.4364

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

Spoilage bacteriay= 0.016x-0.2969

25

100

Time (hours)

11.1

6.3

4.0

2.8

1.6

1.2

1.0

0.69

0.83

0.590.5

0.4

2.0

spoilbac/Chart9 125 3.1 31.0 hrs

382


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™.


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.


DESTRUCTION OF SALMONELLA IN FOOD

1326

Temp. °F (°C)

5D FDA Hamburger (100,000:1)

6.5D FDA Roast beef

(3,160,000:1)

7D USDA Poultry

with 12% 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

DESTRUCTION OF SALMONELLA SPP. IN FOOD

DEATH CONTROLS Time and temperature Nutrients and acids Water activity


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


RETAIL FOODSERVICE SYSTEM PROCESS IDENTIFICATION PROCESSES WITH SIGNIFICANT RISK; ABRREVIATED HACCP PLAN

PREREQUISITES Processes with

Significant Risk Hazard

(biological, chemical, physical) Control

Cook / RTE food handler prepares for work

B: Staphylococcus aureus on skin, Streptococcus in throat, Shigella from feces on fingers

C: None P: Jewelry

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

P: Not allowed.

Get equipment to prepare food

B: Vegetative pathogens C: Leaching heavy metal P: Equipment parts

B: Wash, rinse, sanitize. C: Only stainless steel, wood, FDA plastic. P: Keep equipment repaired.

Buy food to be: Eaten as purchased

B: All pathogens C: All hazards P: All hazards

B: Supplier exclusion. No cross-contamination, H0+ΣI<FSO.

C: Supplier exclusion. No cross-contamination, H0+ΣI<FSO.

P: Supplier exclusion. No cross-contamination, H0+ΣI<FSO.

Raw, cook makes safe

B: Vegetative pathogens and spores C: All hazards P: All hazards

B: Cook washes, ferments, pasteurizes. C: Allergens identified. Additives at safe level. P: Removed.

Store refrigerated food

B: No significant increase C: None P: None

B: Refrigerate at 41ºF; food spoils first.


RETAIL FOODSERVICE SYSTEM PROCESS IDENTIFICATION (CONT'D)

FOOD PROCESS HACCP

Processes with Significant Risk

Hazard (biological, chemical, physical) Control

Cut up raw food on cutting board

B: Cutting board and hands contaminated with pathogens from raw food

C: Chemicals P: Hazards

B: Wash, rinse, sanitize cutting board, hands, and utensils after contact with raw foods.

C: Do not cross-contaminate. P: Remove physical hazards.

Weigh ingredients B: None C: Additives P: None

C: Used at a safe level.

Food to be served without cooking

B: E. coli, Salmonella vegetative pathogens C: None P: None

B: Wash vegetables; ferment; acidify.

Cook B: Vegetative pathogens; cooking activates spores

C: None P: None

B: Pasteurize. Reduce vegetative pathogens 5 log. Keep >130ºF for spore control.

Hot hold B: Spores C: None P: None

B: >130, spores can't germinate.

Cool B: SporesC: None P: None

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. Mix cold ingredients, salad and sandwiches, or reheat

B: Spores, vegetative pathogens C: None P: None

B: Mix <50ºF. Prevent vegetative pathogen cross-contamination.

Take-out B: SporesC: None P: None

B: Control spores by eating in <6 hours if at room temperature or refrigerate.

Cold hold B: Spores C: None P: None

B: Control spores by keeping ≤41°F or, if raw fish, <38°F.


FOOD GROUPS HACCP PROCESS ANALYSIS HACCP Process Groups

(USDA HACCP, 9 CFR 417) Prerequisite / GMPs working

Control

Shelf life

I Not heat treated, not shelf stable (raw). Not PHF / no RPG: sprouts; raw meat, fish; sushi, sashimi; eggs, raw fruits and vegetables

Grown safe, with H0 that meets FSO. May require Temperature Control for Quality.

<14 days (bact. spoilage)

II Not heat treated, with inhibitors to make shelf stable. Water activity: flour, corn meal, nuts, salt, sugar, sugar icing, honey, spices and herbs, oil, lard; salted, dried fish, fresh pasta Fermentation: pepperoni, salami; olives; dairy (cheese, yogurt, sour cream / milk / crème fraîche); bread; sauerkraut; kimchee; beer, wine Acidified: salad dressing; cole slaw; salsa; condiments

Grown safe, made safe by supplier, with H0 that, with +ΣI-ΣR (5-log Salmonella), meets FSO. Does not require TCS because of product aw, pH, or additives.

>2 years, 70ºF (chem. spoilage)

III Fully cooked, not shelf stable. hot or cooled, refrigerated ready-to-eat food; meat, fish, poultry; fruits, vegetables, dairy, pastry filling, pudding

Pasteurized (5-log to 7-log Salmonella) so that +ΣI-ΣR meets FSO. Requires TCS.

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

IV Fully cooked, with inhibitors to make shelf stable. marinara sauce; fruit pie fillings; cake icing, bread and pastry, dry cereals, dry pasta, smoked fish; packaged, low-pH fruits and vegetables

Pasteurized (5-log to 7-log Salmonella) so that +ΣI-ΣR meets FSO. Does not require TCS because of product aw, pH, or additives.

>5 years

V Commercially sterile, shelf stable. "packaged" meat, fish, poultry, fruits, vegetables, dairy / UHT milk

Sterilized, Clostridium botulinum spores reduced 9 log to 12 log. Does not require TCS.

>5 years

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


RETAIL PROCESS HACCP BASED ON FIVE USDA HACCP PROCESSES

Process Purchase Receive / Store Pre-Prep Preparation Transport, Hold, Serve Cool Customer

Consumption 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.

No B,C,P cross-contamination

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

No B,C,P cross-contamination.

No B,C,P cross-contamination.

N/A Raw food spoils safe. No B,C,P cross-contamination.

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.

CCP. Farmer / supplier has HACCP and guarantees safe levels of hazards on food.

No B,C,P cross-contamination

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

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.

III. Fully cooked*, not shelf stable Ready-to-eat meat, fish, poultry, butter, cheese, ice cream, salads with cooked safe ingredients

<103 Salmonella. Chemicals at tolerable levels.

No C,P cross-contamination.

Remove hard foreign objects.

CCP. Cooking gives a 5-log to 7-log Salmonella kill; spores survive. No inhibitors.

CCP. >130ºF. CCP. <6 hours, 120 to 55ºF.

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

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)

<103 Salmonella. Chemicals at tolerable levels.



CCP. Cooking gives a 5-log to 7-log Salmonella kill. pH, aw , and chemical inhibitors prevent spore outgrowth.


V. Commercially sterile**, shelf stable Hermetically / anaerobically packaged food (vegetables, beans, meat, poultry, fish, soup, dairy products)

<1 Clostridium botulinum / gram Chemicals at tolerable levels.



CCP. Product receives a 9-log to 12-log Clostridium botulinum reduction.


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 12-log Clostridium botulinum treatment


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.


READY-TO-EAT CHILLED FOOD PROCESSES 1. ASSEMBLE-COOK-PACKAGE HOT-CHILL Pre-prep assemble Cook pasteurize Pump, package hot, MAP, vacuum, air Chill Stews, sauces, soups, sandwich spreads, fruit pie fillings, pudding

2. ASSEMBLE-SEAR-PACKAGE-COOK-CHILL a. Pre-prep assemble Sear Vacuum package Cook pasteurize Chill Sous vide, rolls and roasts, canned crab and ham b. Pre-prep assemble Package (pan / tray), MAP, vacuum, air Cook pasteurize Chill Casseroles (meat, pasta, vegetable, sauce combination) pates, meat, fruit, and cream pies, quiches

3. COOK-CHILL-ASSEMBLE-PACKAGE a. Pre-prep Cook pasteurize Chill Assemble whole Package, MAP, vacuum, air Roast or fried chicken, other roasts, uncured sausage, bread b. Pre-prep Cook pasteurize Chill Slice / dice assemble Package, MAP, vacuum, air Uncured luncheon meat, diced meat c. Pre-prep Cook pasteurize Chill Assemble (pan / dish / tray) Package, MAP, vacuum, air Meat and pasta, dinners, meat and sauces, sandwiches and pizza, milk d. Pre-prep Cook pasteurize Partial chill?? Fill in dough Chill Package, MAP, vacuum, air Meat pies, quiches, patties, pates, filled pastries

4. ASSEMBLE WITH COOKED AND RAW INGREDIENTS-PACKAGE a. Pre-prep Assemble 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-prep Assemble cold raw / cold pasteurized and hot (liquid) ingredients Package, MAP, vacuum, air Chill / 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.


HACCP FLOWS-CHILLED FOOD PROCESSES


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

Is this step the best CCP? No; 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?

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

Get ingredients

Supplier Safe

Supplier Unsafe; TCS

I. Trim, wash

Yes, TCS II. Additives,

ferment

No TCS

III. Pasteurize

Yes TCS IV. Pasteurize

+ Additives

No TCS

V. Sterilize

No TCS

Combine, Serve


QUALITY-ASSURED HACCP RECIPE PROCEDURES Recipe Name: Chicken Cacciatore

Portion size (vol./wt.): 1/4 (6 oz.) chicken + 3 oz. sauce

Preparation time: 2 hours

Production style: Combination Number of portions: 100 Prepared by: S. P. Written by: O. P. S. Date: 10/95 Final yield (AS):100 Supervisor: SA/QA by: J. Bell Date: 12/95 Final yield:

Gp.

# Ingred.

#

Ingredients and Specifications Edible Portion (EP) (weight or volume)

EP Weight %

As served (weight)

I 1 Onions, chopped (1/2" x 1") 3.0 lb 1,360.00 g 13.26 2 Mushrooms, cut (1/2 ", caps & stems) 3.0 lb 1,360.00 g 13.26 3 Peppers, green, cut (1/2" x 1") 2.0 lb 907.2 g 8.84 4 Garlic, chopped 6 Tbsp. 85.05 g 0.53 5 Tomatoes, canned, crushed

( 2 - #10 cans) 13.25 lb 6,010.00 g 58.58

6 Oil, vegetable 1/4 cup 54.00 g 0.53 7 Wine, Marsala or Madeira 2 cups 472.00 g 4.60 8 Oregano, crushed 2 tsp. 3.00 g 0.03 9 Salt 1 tsp. 5.50 g 0.05 10 Pepper 1 tsp. 2.10 g 0.02

Total 22.6 lb 10,258.85 g 100.00 22.0 lb Approx. gallons 2.5 gal.

II 11 Chickens, whole (25 - 2¼ to 2½ lb.) 62 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. 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

Verif.

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

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.

Ti 40°F To 205°F t 20 min.

1a. Hold in bain marie. D Ti 205°F To 165°F t 20 min.

↓ 2. Get chicken quarters from refrigerator. O Remove rib bones. Ti 40°F To 45°F t 10 min.

↓ 3. CCP Place quarters, one layer deep in O shallow roasting pan. Bake (brown) in

convection oven at 350°F to >165ºF, >15 sec. Ti 45°F To >165°F t 30 min.

↓ 4. Remove pan(s) of chicken from oven. O Pour off excess liquid. Save for chicken

stock. Ti >165°F To 155°F t 15 min.

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 To <41°F t < 6 hr.

↓ 5. Cover chicken quarters with sauce. O Ti 155°F To 150ºF t <10 min.

↓ 6. Bake at 300°F in convection oven until O chicken reaches a temperature of 175°F. Ti 150°F To 175°F t 45 min.

↓ 7. Check. Is the temperature 175ºF? I If not, continue to cook.

No

↓ Yes 8. Cover and transfer to 150°F hot holding unit. T 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. 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. Ti 135ºF To <41ºF t <6 hr.

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

D = Delay I = Inspect O = Operate S = Store T = Transport Ti = Temp. in To = Temp. out t = Time to do the step CCP = Critical Control Point

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)

B, C, P, Potential Hazards and Risk Analysis

Control Critical Limit (CL) for each Hazard Control

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

Corrective Action & Record Verification & Record (Procedures and Frequency)

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.

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.

1a. Hold sauce in bain marie. D Ti 205°F To 165°F t 20 min.


No pathogenic microbial growth in sauce at >130°F.

2. Get chicken quarters from O refrigerator. Remove rib bones. Ti 40°F To 45°F t 10 min.

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

Vegetative pathogens and spores are con-trolled by low temperature. Inspect to assure that all bones are removed

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.

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

Cooking temperature >165°F, >15 sec. assures a >7D salmonellae kill.

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.

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.


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

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.

B: Pathogenic spores C: None P: None

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

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.

5. Cover chicken quarters with O sauce. Ti >155°F To 150°F t<10 min.

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


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.




Process Steps and Controls: GMPs and prerequisites are in place

(Ti=temp. in; To=Temp. out;

B, C, P, Potential Hazards and Risk Analysis

Control Critical Limit (CL) for each Hazard Control

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

Corrective Action & Record Verification & Record (Procedures and Frequency)

t=Time to do the step) 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. Ti 135ºF To <41ºF t <6 hr.

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.

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.

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 __________________________


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.


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™.


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

COOLING TIMES AND TEMPERATURES

FDA 6-Hour Cooling 135 to 41ºF

(38ºF Environment)

USDA Cooling 120 to 55ºF in 6 hours, followed by cooling to 40ºF (38ºF Environment)

0 135 0 1201 94 1 1012 70 2 863 55.8 3 754 48.0 4 665 43.5 5 606 41 6 55

7 518 489 45.5

10 43.911 42.512.6 4114.16 40

1

10

100

0 2 4 6 8 10 12 14 16

Time (hours)

Log 1

0 (Te

mpe

ratu

re D

iffer

ence

(Foo

d C

ente

r Tem

pera

ture

m

inus

Air

Tem

pera

ture

) o F

138

48

39

40

41

424344

46

58

68

788898

118128

10

47

45

Foo

d C

ente

r Tem

pera

ture

(o F)

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

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

temperature reduction

1342


FSMS WITH PROCESS PE1. Ma

7. Food HA Process Safety Objectives

Biological, ChemicaControls: Preven

+ Σ Increase - Σ Reduc Physical hazards: removFruits and vegetables: w

5-log reduction Pasteurize (in package or

5-log Salmonella reducAdditives / dry shelf stablSterilize 250ºF for 3 minu

botulinum reduction Hot hold >130ºF / 135ºF Cool <2-inch pan, <6-inch

Clostridium perfringensCold hold <41ºF, <1-log s

multiplication Acidify, shelf stable pH <4

cereus, <4.6 ClostridiumWater activity, shelf stableaureus, <0.92 Bacillus cer

INPUT Baseline hazards H0

Prerequisite Processes

2. Personnel Double wash, nail brush 6-log reduction 3. Environment 4. Facilities 5. Equipment Pest prevention; Food contact surface wash 5-log / 2-log reduction 6. Supplies Food that the farmer grew / processor made safe; Prevent cross-contamination / allergen identification; Chemical control

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

RFORMANCE STANDARDS nagement

CCP processes / performance standards

l, and Physical Hazards t, Eliminate, Reduce tion pathogen substance

e, reduce <1/16 inch ash 2-log or surface blanch

not) 150ºF for 1 minute for tion e tes for 12-log Clostridium

diameter pot, <1-log multiplication pore / vegetative cell

.2 Salmonella, Bacillus botulinum

<0.86 Staphylococcus eus

OUTPUT FSO / ALOP

Daily Operations Report

8. Products and Services

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

51

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


MENU ITEM HACCP PLAN

Menu Item Storage Preparation Hold / Serve Leftovers Baked potato, raw Dry storage, RT, 10 days. Double wash. Wrap in aluminum foil.

Bake at 400ºF until soft (190ºF) >160ºF, 15 sec. CCP.

Hold >160ºF, <1 hr. / WD. CCP.

None

Charleston chicken, raw

Hold in FD, 0ºF / 24 hrs. Deep fry (350ºF) to >165ºF, 15 sec. CCP.

Serve immediately. None

Chicken wings (buffalo wings), supplier pasteurized

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

Deep fry (350ºF) to >165ºF, 15 sec. CCP.


Chicken fried steak, raw

Hold in FD, 0ºF / 24 hrs. Cook to order. Deep fry (350ºF) to >160ºF, 15 sec. CCP.


Hamburger (Junior Burger, 3 oz.), raw

Frozen, wrapped 24 hrs. / FD. Cook to order, from frozen >160ºF, 15 sec. CCP. (Temperature measurement must assure destruction of E. coli.) (Add seasoning.)


Hashed browns, aw control, supplier pasteurized

Unopened (dry storage, RT). Rehydrated shelf life 24 hrs. including 20 minutes rehydration <40ºF (clock label).

Cook to order >160ºF, 15 sec. Serve immediately. None

Boca Burger, supplier pasteurized

Hold 24 hrs. FD, 0ºF. Cook to order >160ºF, 15 sec. Serve immediately. None

Steak, sirloin / steak T-bone, raw

Frozen / thaw 24 hrs. refrig. Hold 48 hrs. / RD <40ºF (clock label).

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


Eggs, pasteurized liquid, supplier pasteurized

After opening 24 hrs. / WR <40ºF (clock label).

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


Eggs, fried, raw Refrigerated shell eggs (<40ºF). Cook to 145ºF, 15 sec., unless customer requests otherwise. CCP.


Eggs, hard boiled, raw

Refrigerated shell eggs (40ºF). Cook for 10 minutes, >150ºF, 15 sec. Pour ice over eggs to cool. CCP.

24 hrs. refrig. <40ºF. Discard

Oatmeal, aw control, supplier pasteurized

RT storage Mix pack with hot water (>190ºF) or: Kettle, add oatmeal to boiling water, simmer 8-10 minutes <160ºF, 15 sec.

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

Discard


Menu Item Storage Preparation Hold / Serve Leftovers Mashed potatoes, aw control, supplier pasteurized

RT storage Mix 2 qts. boiling water (212ºF), 2 oz. Liquid Margarine and 1 bag potato mix >160ºF, 15 sec.

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

Discard

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

Clean and trim. Double wash. CCP. Cut or dice <40ºF.

<40ºF, 24 hrs. Discard

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

Clean, core, remove brown leaves. Double wash. CCP. Quarter. Separate leaves. Remove excess water. Store in plastic container <40ºF.


Mushrooms, raw, supplier vegetative pathogen safe

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

Double wash. Remove stems. Slice <50ºF.


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

Double wash. CCP. Slice. stack slices in 4-inch insert pan.

8 hrs. / CT <40ºF. Discard

Parsley 7 days refrig. <40ºF (cover label, clock label).

Inspect parsley, remove brown and yellow leaves. Double wash. CCP. Trim parsley to 1-to-1-1/2-inch stems.

Washed, prepped 24 hrs. / CT <40ºF.

Discard

Roast beef, supplier pasteurized

Stored frozen, thaw 24 hrs. / WR (clock label).

Use in sandwiches. 48 hrs. / RD <40ºF. Discard

Cheddar cheese (shred), aw control, supplier pasteurized

5 lb. plastic bags 3 mths. / WR <40ºF.

Use as directed. Portioned 72 hrs. WR 24 hrs. / RD <40ºF.

Discard

Mayonnaise, pH control, supplier pasteurized

1-gal. plastic jar, unopened (store room) = expiration date

Use as directed. Open refrig. = 30 days, not to exceed expiration date. WR <40ºF.

Discard

Iced tea, freshly brewed, supplier safe

Dry storage, RT Prepare as directed. Brewing assures pasteurization.

8 hrs. Discard


STANDARDIZED MONITORING What to Measure How to Measure

Food temperature in cold holding (delivery, receiving, refrigerator)

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

Cooked, pasteurized food Measure temperature of center of thickest food item. Hot hold display Measure 1/8 to 1/4 inch below the top surface. Cooling Push through the thickest part of the food to find the

warmest temperature. Cold hold display Measure 1/8 to 1/4 inch below the top surface Refrigerator air temperature Measure cup of salt, 8 oz., on the center shelf for >1 hour

to stabilize. Oven temperature Measure cup of salt, 8 oz., on the center shelf for >1 hour

to stabilize. Oven humidity Use a thermocouple in a cotton wick in water with air

circulation. Fryer Using a tip-sensitive thermometer, measure oil

temperature for 3 cycles and take the average. Food pH At 20ºC, measure pH with a strip or meter. Food can be

diluted by 30% with distilled water, if needed. Food aw Use a Decagon aw meter or equivalent. Surface safety Using Petrifilm™, do a contact plate or swab and look for

<100 colonies per 8 square inches.


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


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 orrective action; audits to improve c

Prerequisite rocess p

Personnel Wash fecal pathogens off fingertips, 6 log10 reduction; personal hygiene Environment and Facilities

Clean; no pests

Equipment Food contact surfaces: rinse, wash, rinse, sanitize, 5 log10 reduction

Supplies 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,

asteurized food p

41ºF, 7 days <50ºF, <3 log10 increase of Bacillus cereus (>30 days)

Reheat 41 to 165ºF, <2 hours None; process must prevent toxin


EXCELENT HACCP

Documents