8/3/2019 HACCP Food Safety Pp11 30 Rev10 02
1/20
DESIGNING A FOOD SAFETY PLAN BASED ON HACCP
This manual is adapted from the ServSafe Course Book, Chapter 9, Principles of HACCP System, National Restaurant
Association Education Foundation 1999.
8/3/2019 HACCP Food Safety Pp11 30 Rev10 02
2/20
12
8/3/2019 HACCP Food Safety Pp11 30 Rev10 02
3/20
13
I. INTRODUCTION: WHAT IS HACCP?
Hazard Analysis Critical Control Point (HACCP) is a system of food safety that treats receiving, storage, prepa-
ration and service of food as a continuous system or flow. Each step is broken down into a logical component
and is evaluated by principles of risk. The premise is simple: If each step of the process is carried out correctly,
the end product will be safe food.
HACCP is based on the principle that if biological, chemical or physical hazards can be identified at any step of
the flow of food, they can be prevented, eliminated, or reduced to safe levels.
Prerequisite programs or Standard Sanitation Operating Procedures (SSOPs) are the basics of serving safe food.
These include checks such as cleaning schedules, use of correct concentrations of chemical sanitizers, and
proper refrigeration temperatures. Section II of this manual describes the SSOPs and provides sample check
sheets for daily, weekly and monthly cleaning and maintenance.
Part of the SSOPs is Employee Training and Personal HygienePolicies. Section III asks basic questions to
consider when developing these policies.
Once the prerequisite standards are complete, the actual menu analysis and flowcharting can begin. Section IV
is a self-help guide to the process steps to take you to HACCP:
Step 1: Assess the HazardsA series of questions focused on the menu
Step 2: Identify Critical Control Points (CCPs)Forms included for a complete flow of potentially
hazardous foods
Step 3: Set up Critical Limits and Standards for CCPsA list of limits and standards included
Step 4: Monitor and DocumentSample forms included
Step 5: Corrective ActionsStep 6: Set up a record-keeping system
Step 7: Verification of the System
Your Food Safety Plan is as individualized as your menu. There are no standard forms that fit all needs. The
examples in this manual can be used in total, modified or redesigned to meet the needs of each individual
operator.
This is not a project that will be completed within a week or two, or even a couple of months. Depending upon
your menu, it could take six months or more. Take your time and train as you go. This is a project that should
include the key people of your food service team. Your Environmental Health Specialist is also available forconsultation.
8/3/2019 HACCP Food Safety Pp11 30 Rev10 02
4/20
14
II. STANDARD SANITATION OPERATING PROCEDURES (SSOPs)
SSOPs are a prerequisite to the HACCP plan. These are written procedures designed to ensure that unsanitary
conditions do not introduce hazards into the end product. HACCP specifically requires that these procedures
eliminate or reduce hazards from occurring in areas where food is exposed, before and after Critical Control
Points (CCPs) such as cooking, cooling, and re-heating standards have been implemented.
The following questions will assist you in evaluating your current SSOPs and assessing if all areas are ad-
dressed. Additionally, they can serve as a monitoring tool once your SSOPs are in place. Monitoring compli-
ance to your SSOP plan should be conducted at least once per month.
Sample forms of different cleaning schedules can be found in the appendix. Your forms should be designed for
your establishment needs. A schedule provides employee accountability for the completion of the tasks.
The following forms (located in the appendix) are available to help you monitor the SSOPs discussed here:
Weekly Cleaning Schedule
Monthly Cleaning Schedule
Dry Storage and Maintenance
Refrigeration and Food Handling
Handwashing, Warewashing and Cleaning
Master Cleaning Schedule and Sample Cleaning Schedule
Are there established cleaning schedules for maintenance staff and for line staff? (Refer to cleaning sched-
ule located in the appendix.)
Inform everyone: whatis to be cleaned, who is responsible to clean it, when or how often it is to be
cleaned, and how to clean it.
Assign staff member(s) to monitor the cleaning.
(Refer to sample cleaning schedule)
What are the sanitizing standards?
Train the responsible persons
(dishwashers) on the standards
(e.g., final rinse temp on the
dishmachine, or PPM of sanitizers
in the three-compartment sink and
the sanitizing bucket). Develop a
log for dishwashers to record thefinal rinse temp, or the concentra-
tion of chlorine on the machine at
least once daily. Provide instruc-
tions for manual dishwashing
regarding the correct amount of
chemical to use.
Assign staff member(s) to monitor
these readings.
8/3/2019 HACCP Food Safety Pp11 30 Rev10 02
5/20
15
What are the equipment maintenance standards?
Follow schedules for routine maintenance.
Know how often the exhaust hood and refrigerations condensers are required to be cleaned.
Check thermometers in refrigeration equipment regularly.
Check the cooling equipment routinely and calibrate if necessary.
Check cooking and hot holding equipment routinely and calibrate if necessary.
Operate warewashing equipment according to manufacturers standards.
What are your personal hygiene standards?
Ensure that handwashing facilities are available. Be sure there are
enough for an establishment of your size. Properly equip them with
soap, towels, and nailbrushes. Assign someone to be responsible for
filling the soap and towel dispensers.
Toilet facilities must be accessible and maintained.
Do you have an effective pest control policy?
Are chemicals properly labeled, stored, and safely used?
Contaminants such as lubricants, cleaning compounds, sanitizing agents
and other toxic materials must be stored and used properly.
Food packaging materials and other physical hazards such as broken
glass from light fixtures must be controlled.
III. EMPLOYEE TRAINING/PERSONAL HYGIENE
The following forms (located in the appendix) are available to help you monitor the SSOPs discussed here:
Employee Illness Log
Handwashing, Warewashing, and Cleaning Log
Outline the employee training programs currently in place.
Is an outside trainer needed?
Are there records indicating who attended each training?
Do employees know how to use and calibrate a thermometer?
Are there written personal hygiene standards, including when and how to wash hands?
Are standards given to each employee and do they initial a record indicating they understand?
What is the employee illness policy? The City of Minneapolis enforces the Minnesota Food Code, and it is
specific regarding ill employees (see page 54).
Is there an employee illness log? Minnesota Food Code now requires that a log be maintained for employ-
ees who report of illness involving vomiting or diarrhea.
Has there been MSDS (Material Safety Data Sheets) orientation? Are there logs indicating who attended
and the date? Are sheets accessible by employees?
8/3/2019 HACCP Food Safety Pp11 30 Rev10 02
6/20
16
IV. CREATING YOUR INDIVIDUALIZED FOOD SAFETY PLAN
CONCEPTS AND DEFINITIONS
Hazards: Biological, chemical, or physical agents that may cause illness or injury if not controlled throughout
the flow of food.
Hazard analysis: The process of identifying and evaluating possible hazards associated with foods in order todecide which foods must be addressed in a HACCP plan.
Control Point (CP): Any step in the flow of food where a physical, chemical, or biological hazard can be
controlled.
Critical Control Point (CCP): The last step where you can intervene to prevent, control, or eliminate a biologi-
cal hazard is before the food is served to customer.
Critical limit: Minimum and maximum limits that the CCP must meet in order to prevent, eliminate, or reduce a
hazards to an acceptable level (e.g., a final cook, hold, or cooling temperatures.)
Monitoring: The process of analyzing whether your critical limits are being met and you are doing things right,
such as taking temperatures at each CCP.
Corrective action: A predetermined step taken when food doesnt meet a critical limit.
Again, here are seven steps to this HACCP-based food safety system.
1. Assess the Hazards. Analyze your menu and assess risks.
2. Identify Critical Control Points (CCPs)
3. Set up Critical Limits and Standards for CCPs
4. Monitoring and Documentation
5. Corrective Action
6. Documentation
7. Verification of your System
8/3/2019 HACCP Food Safety Pp11 30 Rev10 02
7/20
17
STEP 1. ASSESS THE HAZARDS
A. Analyze your menu.
List potentially hazardous foods and group them into process specific lists: (1, 2, or 3)
1. No Cook StepReceive/Store/Prep/Serve;
2. Food Prep for Same Day ServiceReceive/Store/Prepare/ Cook/Serve; or
3. Complex Food PrepReceive/Store/ Prep/Cook/Hold/Cool/Reheat/Serve.(See example of HACCP Flow of Food Flowchart on the next page.)
The HACCP Flowchart on the next page shows the ways that food flows through an establishment.
Menu Item Process List #
__________________________________________________________ _________________
__________________________________________________________ _________________
__________________________________________________________ _________________
__________________________________________________________ _________________
__________________________________________________________ _________________
__________________________________________________________ _________________
__________________________________________________________ _________________
__________________________________________________________ _________________
__________________________________________________________ _________________
__________________________________________________________ _________________
__________________________________________________________ _________________
__________________________________________________________ _________________
__________________________________________________________ _________________
__________________________________________________________ _________________
__________________________________________________________ _________________
__________________________________________________________ _________________
__________________________________________________________ _________________
__________________________________________________________ _________________
__________________________________________________________ _________________
8/3/2019 HACCP Food Safety Pp11 30 Rev10 02
8/20
18
HACCP FLOW OF FOOD FLOWCHART
COOLER
RECEIVING
STORING
DRY STORAGECOOLERFREEZER
PREP
COOK
SERVECOOL HOLD
REHEAT
SERVE
PREP
SERVE
REHEAT
COOLSERVE
SERVE
8/3/2019 HACCP Food Safety Pp11 30 Rev10 02
9/20
19
B. What are the hazards associated with these foods? (See list of hazards on the next page.)
Menu Item Step in the Flow Hazard(s)
__________________________________ _______________ __________________________
_______________ __________________________
_______________ __________________________
__________________________________ _______________ __________________________
_______________ __________________________
_______________ __________________________
__________________________________ _______________ __________________________
_______________ __________________________
_______________ __________________________
__________________________________ _______________ __________________________
_______________ __________________________
_______________ __________________________
__________________________________ _______________ __________________________
_______________ __________________________
_______________ __________________________
__________________________________ _______________ __________________________
_______________ __________________________
_______________ __________________________
__________________________________ _______________ __________________________
_______________ __________________________
_______________ __________________________
__________________________________ _______________ __________________________
_______________ __________________________
_______________ __________________________
__________________________________ _______________ __________________________
_______________ __________________________
_______________ __________________________
This form can be duplicated if needed for large menus.
8/3/2019 HACCP Food Safety Pp11 30 Rev10 02
10/20
20
IDENTIFICATION OF HAZARDS
BIOLOGICAL
CHEMICALChemical contamination can be caused by pesticides, food additives and preservatives, cleaning and sanitiz-
ing supplies and toxic metals that leach through worn cookware and equipment. Lubricants used for equip-
ment, paints or petroleum products, and personal care items can be contaminated.
PHYSICAL
Including dirt, hair, broken glass, nails, staples, metal fragments, bandaids, and finger cots.
Uncooked Foods
Poultry Products, raw
Red Meats, raw or undercooked
Fish & Shellfish, raw or undercooked
Vegetables, Fruits
(including sprouts, all melons, raspberries,
garnishes, lettuce)
Pathogen
Salmonella, Camplylobacter
Salmonella, E. coli, Campylobacter
Salmonella, Listeriosis, Norwalk Virus,
Diarrhetic Shellfish Poisoning, Vibro
Parahaemolyticus, Anisakiasis Hepatitis A
Norwalk Virus, Shigellosis, Salmonella,
Cryptosporidium, Cyclosporosis
Cooked FoodsMeat, Poultry, Gravy, Sauces
Meat-Containing Soups
Fish & Shellfish
Beans, Rice, Pasta, Cornmeal Dishes
Cooked Vegetables
PathogenClostridium Perfringens, Bacillus Cereus
Staphylococcal Intoxication
Ciguatera Poisoning
Bacillus Cereus (2 forms), Clostridium
Perfringens
Bacillus Cereus
Pesticides
Only your Pest Control Operator should be
applying chemicals.
Additives & Preservatives
Sulfiting agentsMonosodium Glutamate (MSG)
Toxic Metals
Including lead, copper, brass, zinc coating
found on enamelware, or galvanized
containerslead-glazed ceramics.
Foodservice Chemicals
8/3/2019 HACCP Food Safety Pp11 30 Rev10 02
11/20
21
C. Estimate the risks.
Who is your customer base? Does it include elderly, children, or persons with compromised immune
systems?
D. Who are your suppliers? If required, are they reputable and certified?
E. Do you have the proper equipment and facilities to serve complicated or multi-step recipes? How will you
maintain proper temperatures at each step of preparation?
F. How are your employees trained?
G. Look at the recipe and procedure for the foods you have chosen and fill in the flowchart on the next page.
Make copies and use separate form for each menu item. Refer to HACCP Flow of Food Flowchart on
the previous page for the steps in the process.
8/3/2019 HACCP Food Safety Pp11 30 Rev10 02
12/20
22
This form can be duplicated for additional food items.
Menu Item Flow Chart
MENU ITEM:
INGREDIENT 1 INGREDIENT 2 INGREDIENT 3 INGREDIENT 4
STEP IN THE FLOW
RECEIVING
Hazard
Standard (CCP?)
Corrective Action
Monitored By
STORAGE
Hazard
Standard (CCP?)
Corrective Action
Monitored By
PREP
Hazard
Standard (CCP?)
Corrective Action
Monitored By
COOK
Hazard
Standard (CCP?)
Corrective Action
Monitored By
8/3/2019 HACCP Food Safety Pp11 30 Rev10 02
13/20
23
Menu Item Flow Chart (continued)
MENU ITEM:
INGREDIENT 1 INGREDIENT 2 INGREDIENT 3 INGREDIENT 4
STEP IN THE FLOW
COOL
Hazard
Standard (CCP?)
Corrective Action
Monitored By
HOLD
Hazard
Standard (CCP?)
Corrective Action
Monitored By
COOL
Hazard
Standard (CCP?)
Corrective Action
Monitored By
REHEAT
Hazard
Standard (CCP?)
Corrective Action
Monitored By
8/3/2019 HACCP Food Safety Pp11 30 Rev10 02
14/20
24
STEP 2. IDENTIFY CRITICAL CONTROL POINTS (CCPs)
A Critical Control Point (CCP) is a step in the food flow that will eliminate, reduce or minimize hazards. (The
three hazards of concern are biological, chemical, or physical). Examples of a CCP are cooking, holding,
cooling, and reheating temperatures.
Critical control points differ for each kind of food and method of preparation. Although not necessary at every
stage in the food flow, they are necessary at one or more stages. For example, receiving raw chicken is not aCCP because at this step you would do nothing to eliminate, reduce or minimize the hazards of salmonella or
campylobacter. (Receiving raw chicken would be a CP or control point that would be established to meet your
standards for safety and quality.) Receiving wouldbe a CCP for ready-to-eat foods such as pasta salads, sliced
meats, or raw oysters, and the critical limit would be a temperature of 41F or less.
Return to your flowchart and insert the CCPs.
STEP 3. SET UP CRITICAL LIMITS AND STANDARDS FOR CCPs
A control standard for the CCP is called a critical limit.
v Receiving standards
For all items
All foods received from an approved source
All packaging intact and in good condition
Frozen Foods
Received frozen
No evidence of thawing and re-freezing
No expired use-by dates
Normal color
Normal texture
Dairy products
Receive at 41F or lower, unless otherwise specified by law
Milk: sweetish flavor
Butter: sweet flavor, uniform color, firm texture
Cheese: typical flavor and texture and uniform color
Eggs (shell)
Receive at an air temperature of 45F or lower
Odorless
Clean and unbroken shells
Condition: firm, high yolks that are not easy to break and whites that cling to the yolk
8/3/2019 HACCP Food Safety Pp11 30 Rev10 02
15/20
25
Raw Meat
Receive at 41F or lower
Beef Color: bright cherry red
Lamb Color: light red
Pork color: pink lean meat, white fat
Texture: firm and springs back when touched
Poultry
Receive at 41F or lower on ice
Color: no discoloration
Texture: firm and springs back when touched
Odor: none
Fish
Receive at 41F or lower
Color: bright red gills; bright shiny skin
Odor: mild ocean or seaweed smell
Eyes: bright, clear, and full
Texture: firm flesh that springs back when touched
Shellfish (clams, mussels, oysters)
Receive at 45F or lower
Odor: mild ocean or seaweed smell
Shells: closed and unbroken (indicates shellfish are alive)
Condition: if fresh, they are received alive
Crustacea (lobster, shrimp, crabs)
Receive at 45F or lower
Odor: mild ocean or seaweed smell
Shells: hard and heavy for lobsters and crabs
Condition: if fresh, they must be received alive; packed with seaweed and kept moist
Fresh Produce
Receiving temperatures vary with each produce item
Cut melon is a potentially hazardous food and must be received at 41F or lower
Canned Foods
Can and seal are in good condition
Processed Foods (Modified Atmospheric Packaging (MAP), shrink wrap, etc.)
Refrigerated: receive at 41F or lower, unless specified by the manufacturer
Frozen: frozen foods should be received frozen
8/3/2019 HACCP Food Safety Pp11 30 Rev10 02
16/20
26
v Storage Standards
Storage areas should be positioned to prevent
contamination.
Keep potentially hazardous food out of the tem-
perature danger zone, 41F to 140F.
Follow FIFO: first in, first out.
Potentially hazardous ready-to-eat foods should be
discarded if not used within seven days of prepara-
tion.
Check the temperature of stored foods and storage
areas regularly.
Store food only in designated storage areas and
store 6 inches off the floor.
Keep storage areas clean and dry.
Keep all goods in clean, undamaged wrappers,packages, or containers that are labeled with date
opened or received, contents, and expiration date.
Clean carts or other vehicles that transport food.
Transfer food between containers properly.
v Pre-preparation standards
Thawing
In a refrigerator, at temperatures of 41F or lower.
Submerged under running potable water, at a temperature of 70F or lower.
In a microwave oven, if the food will be cooked immediately after thawing.
As a part of a cooking procedure, as long as the product meets the required minimum internal
cooking temperature.
Preventing Cross-Contamination
Prepare raw meats, fish, and poultry in separate areas from produce or cooked and ready-to-eat
foods.
Assign specific equipment (cutting boards, utensils, and containers) to each type of food product.
Clean and sanitize all work surfaces, equipment, and utensils after each task.
Make sure cloths or towels used for wiping spills are not used for any other purpose.
Make sure employees wash their hands between tasks.
Consider using single-use disposable gloves when preparing or serving food.
Washing Produce
Wash fruits and vegetables thoroughly under running water before cutting, cooking, or combining
with other ingredients.
8/3/2019 HACCP Food Safety Pp11 30 Rev10 02
17/20
27
v Preparation standards
Cooking Critical Limits
Poultry: 165F for 15 seconds
Pork: 155F for 15 seconds
Ground or flaked meats: 155F for 15 seconds
Beef and pork roasts: 145F for 15 seconds
Beef steaks, veal, lamb, commercially raised game animals: 155F for 15 seconds
Fish: 145F for 15 seconds
Shell eggs: 145F for 15 seconds
Preventing Cross-Contamination
Prepare raw meats, fish, and poultry in
separate areas from produce or cooked and
ready-to-eat foods.
Assign specific equipment (cutting boards,
utensils, and containers) to each type of
food product.
Clean and sanitize all work surfaces,
equipment, and utensils after each task.
Make sure cloths or towels used for wiping
spills are not used for any other purpose.
Make sure employees wash their hands
between tasks.
Consider using single-use disposable gloves when preparing or serving food.
Washing Produce
Wash fruits and vegetables thoroughly under running water before cutting, cooking, or combining
with other ingredients.
Cold food critical limits
Refrigerate and hold potentially hazardous foods at 41F or lower.
8/3/2019 HACCP Food Safety Pp11 30 Rev10 02
18/20
8/3/2019 HACCP Food Safety Pp11 30 Rev10 02
19/20
29
v Reheating
Reheat food to 165F for 15 seconds within two hours.
Prepare raw meats, fish, and poultry in separate areas from produce or cooked and ready-to-eat
foods.
Assign specific equipment (cutting boards, utensils, and containers) to each type of food product.
Clean and sanitize all work surfaces, equipment, and utensils after each task.
Make sure cloths or towels used for wiping spills are not used for any other purpose.
Make sure employees wash their hands between tasks. Consider using single-use disposable gloves when preparing or serving food.
8/3/2019 HACCP Food Safety Pp11 30 Rev10 02
20/20
STEP 4. MONITORING
The HACCP Daily Temperature Log, and HACCP Time/Temperature Log for Cooling and Reheating Potentially
Hazardous Foods are located in the Appendix.
What critical limits are you measuring?
Who will monitor and how often will it be monitored?
Having CCPs and critical limits are meaningless without monitoring and documentation. Employeesneed training about the importance of monitoring temperatures. They should be involved in estab-
lishing your HACCP system so they understand its importance to your total food safety program.
STEP 5. CORRECTIVE ACTION
When you discover your standards for a critical control point are not being met, it is necessary to take corrective
action immediately.
The type of corrective action will depend a great deal upon your methods of preparation, holding and service.
Analysis of the flowchart will also provide clues. Document the corrective action taken and analyze what
caused the problem and what future actions must be taken to prevent its re-occurrence.
STEP 6. DOCUMENTATION
Forms (HACCP Daily Temperature Log, and HACCP Time/Temperature Log for Cooling and Reheating Poten-
tially Hazardous Foods) are located in the appendix.
Accurate documentation provides a source of information about your daily operations and also shows that your
standards are being met and that you are addressing problems. These records are extremely valuable if a
foodborne illness is alleged or does occur.
Maintain the records in a special book and include flowcharts, SSOPs, and three months of logs.
STEP 7. VERIFICATION OF YOUR HACCP SYSTEM
Each time you add or change the preparation steps of a menu item, revisit your HACCP plan. Review logs to
determine if employees are committed to the plan. You may discover dry lab, or data entries made without
taking actual measurements. This will be an indication that you need to change supervisory techniques, em-
ployee training, or to achieve more personal involvement from your staff.
Ask your district Environmental Health Specialist to review your plan for verification and to provide food code
information or to provide in-house training for your employees.