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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
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THE UNIT AS A FOOD PROCESS SYSTEM
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FOOD SAFETY MANAGEMENT SYSTEM (TRAINING) MANUAL Preface Log of changes Reassessment Operations Description System description Organization Environment (picture) Facilities (plan) Equipment (list) Menu HACCP (processes) AMC-HACCP Management Food safety policy Responsibility and
accountability HACCP team / QC Self-inspection Corrective action Training Emergencies Food security / sabotage
Prerequisite Processes Personal hygiene Employee illness reporting Hand washing After toilet After touching raw food Facilities, Environment Cleaning, maintenance, and
pest control Equipment Cleaning and maintenance of
food contact surfaces Supplies Source of supply Ingredients Supplier safe vs. cook made
safe Receiving inspection Storage: ambient, refrigerated,
frozen Control of physical, chemical,
and biological contamination
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
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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)
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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
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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
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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
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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)
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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.
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FOOD HAZARDS (H0) AND FOOD SAFETY OBJECTIVES (FSO) Hazards
Raw Product Contamination
(H0)
Process Performance Criteria (ΣR)
Food Safety Objective (FSO)
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
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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
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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)
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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
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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
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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
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KITCHEN CLEANING AND SANITATION FOR LISTERIA CONTROL
HAZARD: It must be assumed that the kitchen environment will be colonized with Listeria monocytogenes (Lm). The food contact surfaces in the cook-chill assembly and packaging departments for ready-to-eat food must be cleaned so that there is no measurable Lm (<1 CFU / 25 grams of food).
CONTROL 1. Determine the niches in the equipment in the ready-to-eat assembly and packaging areas where Lm might
become colonized. 2. Establish a cleaning plan for this area. 3. Chose a control alternative
a. Add a Lm chemical growth inhibitor such as sodium diacetate or potassium lactate and also, do a 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. .
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FOOD CONTACT SURFACE WASHING HACCP (cutting boards, knives)
Hazard: Campylobacter jejuni from chicken (1,000 to 10,000 on surface) and Vibrio from seafood Control: 1. With warm water running over the
cutting board into a disposal, scrub with a brush for a few seconds; 3 log reduction by dilution
2. In the pot and pan sink, scrub again; 2 log reduction by dilution
3. Rinse to remove soap 4. Sanitize, air dry Validation: 1. Put 7 log E. coli on the cutting board 2. Wash and sanitize 3. Swab 8 square inches, <10 E. coli
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FOOD RECEIVING AND STORAGE HACCP
Hazard: Pathogens from raw food can cross-contaminate ready-to-eat food. Control: •
• •
•
•
Raw food: time and temperature not CCP; washing or cooking makes food safe Ready-to-eat food on top Air flow: 50 feet per minute holding; 1,000 feet per minute cooling; 41ºF, 7 days; 45ºF, 4 days; 50ºF, 2.5 days; 70ºF, 18 hours; 110ºF, 4 hours Humidity 70% to prevent mold growth; 95% to prevent drying of fruits and vegetables
Validation:
Instant mashed potatoes with E. coli in a container; Store, measure temperature, measure growth
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FDA VS. HACCP PROCESS CONTROL STANDARDS Process Step 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.
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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
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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
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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
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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
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POTENTIALLY HAZARDOUS FOOD / TEMPERATURE CONTROL FOR SAFETY The goal is to measure and control the process capability to the time of consumption, to achieve the following food safety objectives: Vegetative Cells Staphylococcus aureus <3 log growth or no detectable toxin;
H0 ≤2 log in ready-to-eat food Listeria monocytogenes <1 log growth (Ross says ≤100 /
gram at consumption) Salmonella <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
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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
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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
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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
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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
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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
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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
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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™.
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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.
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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
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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
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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.
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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.
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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
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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.
No C,P cross-contamination.
Remove hard foreign objects.
CCP. Cooking gives a 5-log to 7-log Salmonella kill. pH, aw , and chemical inhibitors prevent spore outgrowth.
No hazard. No hazard. No hazard.
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.
No C,P cross-contamination.
Remove hard foreign objects.
CCP. Product receives a 9-log to 12-log Clostridium botulinum reduction.
No hazard. No hazard. No hazard.
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
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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.
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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.
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HACCP FLOWS-CHILLED FOOD PROCESSES
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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
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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.
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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.
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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.
B: Not significant. C: None. P: None.
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.
B: Not significant. C: None. P: None.
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.
Temperature >130°F controls spores and kills vegetative cells.
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.
B: Not significant. C: None. P: None.
Temperature >130°F controls spores and kills vegetative cells.
7. Check. Is the temperature I 175ºF? If not, continue to cook.
B: Not significant. C: None. P: None.
Temperature >130°F controls spores and kills vegetative cells.
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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.
B: Not significant. C: None. P: None.
Temperature >130°F controls spores and kills vegetative cells.
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.
B: Not significant. C: None. P: None.
Temperature >130°F controls spores and kills vegetative cells.
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 __________________________
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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.
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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™.
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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
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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
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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
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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.
Serve immediately. None
Chicken fried steak, raw
Hold in FD, 0ºF / 24 hrs. Cook to order. Deep fry (350ºF) to >160ºF, 15 sec. CCP.
Serve immediately. None
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.)
Serve immediately. None
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.
Serve immediately. None
Eggs, pasteurized liquid, supplier pasteurized
After opening 24 hrs. / WR <40ºF (clock label).
Cook to order (scrambled eggs, omelets) to >150ºF, 15 sec.
Serve immediately. None
Eggs, fried, raw Refrigerated shell eggs (<40ºF). Cook to 145ºF, 15 sec., unless customer requests otherwise. CCP.
Serve immediately. None
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
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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.
<40ºF, 24 hrs. Discard
Mushrooms, raw, supplier vegetative pathogen safe
3 days refrig. <40ºF (cover label, clock label)
Double wash. Remove stems. Slice <50ºF.
<40ºF, 24 hrs. Discard
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
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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.
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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
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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
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