7/14/2005 IFT05-fd-safe-principles 1

FOOD SAFETY PRINCIPLES IN DEVELOPING PRODUCTS

FOR THE FOODSERVICE MARKETSession 25: Enhancing product development success

by combining food science and culinary arts

PRESENTED AT IFT ANNUAL MEETING AND FOOD EXPO

NEW ORLEANS, LOUISIANA, JULY 18, 2005

O. Peter Snyder, Jr., Ph.D.Hospitality Institute of Technology and Management

670 Transfer Road, Suite 21ASt. Paul, Minnesota 55114 USA

TEL 651 646 7077 FAX 651 646 5984osnyder@hi-tm.com http://www.hi-tm.com

7/14/2005 IFT05-fd-safe-principles 2

RETAIL PROCESS INNOVATIONThe retail chef innovates new processes and products.

However, today, the chef must adhere to FDA-dictated process controls whereby specified hazards associated with a process are not always identified; critical levels for safety are not identified; the Food Safety Objective is zero illnesses; and equipment selection is often limited to NSF.

The FDA says, if a retail food operation implements HACCP and does its own scientifically correct process development, it can do any federal process. Unfortunately, the HACCP literature gives no specific food science principles for productinnovation.

This symposium is intended to a provide a source of HACCP information that retail food operators can follow to develop new processes that meet specific Food Safety Objectives.

7/14/2005 IFT05-fd-safe-principles 3

USING AMC-HACCP, AN OPERATOR CAN DO ANY PROCESS VALIDATED AS SAFE BY THE OPERATOR.

• Minimally processed, cook-store (for 45+ days) foods such as sous vide / vacuum-packed, chilled foods with shelf lives determined by the operator vs. cook-serve.

• Processes modified to conserve cooking and refrigeration energy • Food holding 41ºF, 7 days; 45ºF, 4 days; 50ºF, 2.4 days; 55ºF, 1.7 days, etc.• Selling food prepared in a home if the home cook is trained. • Thawing on the counter at room temperature (USDA). • Simplified dish machine operation. • Simplified fruit and vegetable washing (modified dish machine). • Pasteurizing all food beginning at 130ºF.• Peking duck room-temperature skin drying, 12 hours.• Garlic-flavored oil for the table• Korean rice cakes, room-temperature display, 24 hours.• Cooling food in 15 hours to 40ºF.• Fingertip rinse procedure in 1 gallon of water.• Pumping roasts and turkey up to 20% (USDA).• Fermented foods: sausage, cheese, yogurt, sauerkraut, kimchee, beer, wine,

vinegar.

7/14/2005 IFT05-fd-safe-principles 4

THE RAW FOOD CONTAMINATION PROBLEM

1370

7/14/2005 IFT05-fd-safe-principles 5

NATIONAL ADVISORY COMMITTEE ON MICROBIOLOGICAL CRITERIA FOR FOODS (NACMCF) Logic sequence for the application of HACCP to wholesale processing

PREREQUISITE PROGRAMS: Form the HACCP team; identify the system, products, services, customers, and processes, GMPs, etc.

PROCESS HACCP1. Conduct the hazard analysis. Identify process steps with hazards and level of the

hazard.(1) Do a risk analysis and decide which hazards are unacceptable risks.(1)

2. Apply HACCP decision tree to each step with unacceptable risks. Determine which steps are critical control points.

3. Establish critical limits for preventive measures associated with each CCP.4. Establish CCP monitoring requirements. Establish procedures for using the results

of monitoring to adjust the process and maintain control.5. Establish corrective action to be taken when monitoring indicates that there is a

deviation from an established critical limit.6. Establish procedures for verification that the HACCP system is working correctly.7. Establish effective record keeping procedures that document the HACCP system.

1, 2, 3, etc.Y/N1.

HACCP records

Verification procedures /

person(s) responsible

Corrective actions(s) / person(s)

responsible

Monitoring procedures / frequency / person(s)

responsible

Critical limits

Chemical, physical, biological hazards

CCPProcess step

7/14/2005 IFT05-fd-safe-principles 6

THE KITCHEN HACCP TEAMDOES A NACMCF-STYLE HACCP PLAN WITH RISK MANAGEMENT

Not sig sigSTEP

Verification and

Improvement

Corrective Action (by

HACCP team)

Monitoring / Self-Check

Hazard Control

B,C,P Hazard Analysis / Risk Assessment

CCP Step Description

STEP

1. Specify ingredients and flow chart the process / recipe.2. At each step, ask:

a. Is there a B,C,P hazard that can be at a level to make people ill, and is this the correct step to control it? Is it cost effective to control?

b. If yes, what validated control do we use?c. How does the cook monitor to verify control?d. If we lose control, what corrective action rules do we apply?e. How do we verify that we have control?

7/14/2005 IFT05-fd-safe-principles 7

FOOD OPERATIONS RISK CONTROL MANAGEMENT

1904-ov&risk:food-op-haz-cont

• Risk = the likelihood of a hazard injuring a customer x the severity• Risk management is the responsibility of the owner / manager / chef (not regulatory

officials) to provide an Appropriate Level of Protection (ALOP) to their customers. Food liability insurance is for the residual low probability of an unanticipated event.

• Effective control of significant hazards is when a trained cook follows validated procedures to control hazards for an ALOP. The cook is then given positive reinforcement, and processes are evaluated periodically for improvement.

7/14/2005 IFT05-fd-safe-principles 8

THE OCCURRENCE OF AN ILLNESSREQUIRES MANY ERRORS.

Raw food is very contaminated, but very few meals cause illness.Why?

The customer must be

susceptible to the level

of the pathogen, and the

illness must be severe

The cook must not

correct the problem

OR management

must not observe and prevent the

problem

In the kitchen, the pathogen must be given time to multiply

(except Campylobacter

spp.) OR

the cook must cross-

contaminate OR

undercook

The fruit, vegetable, meat must

become contaminated

with a pathogen in

harvest / slaughter

The farmer must

have a colonized

animal

P5xP4xP3xP2xPT = P1

7/14/2005 IFT05-fd-safe-principles 9

POTENTIAL HAZARDS IN THE FOODCHEMICALPoisonous SubstancesToxic plant materialIntentional additivesChemicals created by the processAgricultural chemicalsAntibiotic and other drug residues Unintentional additivesSabotage / terrorismEquipment leachingPackaging leachingIndustrial pollutantsHeavy metalsRadioactive isotopesAdverse Food Reactions(food sensitivity)Food allergensFood intolerancesMetabolic disorderPharmacological reactionsIdiosyncratic reactionsAnaphylactoid reactions

BIOLOGICALMicroorganisms and their ToxinsBacteria: vegetative cells and sporesMolds (mycotoxins, e.g., aflatoxin)Yeasts (Candida albicans)Viruses and rickettsiaParasitesFish and shellfish as sources of toxic compoundsPests, animals (birds, insects and rodents) as carriers of pathogens Filth from insects, rodents, and any other unwanted animal parts or excreta

PHYSICALHard Foreign ObjectsGlassWoodStonesMetalPackaging materialsBonesBuilding materialsPersonal effectsFunctional HazardsParticle size deviationPackaging defectsSabotageChoking / Food Asphyxiation HazardsPieces of food Thermal HazardsFood so hot that it burns tissue

7/14/2005 IFT05-fd-safe-principles 10

PROCESS HACCP IS NOT JUST SEVEN PRINCIPLESHACCP has no process performance criteria / numbers. Applying HACCP principles, one uses food science to specify and develop process performance criteria and to set controls in a new process so as to achieve a desired consumer Appropriate Level of Protection (ALOP) / Food Safety Objective (FSO) (e.g., illness per 100,000 people; deaths per 1,000,000 people).

Biological, chemical, and physical contamination (baseline)Food from the farm

Distribution

Ingredient specifications (to reduce level of hazardsHazard and risk analysis to determine significant hazardsControl; to reduce significant hazards to an ALOPMonitoring to assure process stability and capability

Processor / kitchen

Food Safety Objective (FSO)

Consumer Appropriate level of protection (ALOP)

Process step example using process safety management language:Cook for a 5D reduction of Salmonella to get <1 Salmonella / 100 g

(Control measure) (Performance criterion) (Performance objective)

7/14/2005 IFT05-fd-safe-principles 11

HAZARD FOOD SAFETY OBJECTIVES

7/14/2005 IFT05-fd-safe-principles 12

THE RETAIL FOOD SAFETY MANAGEMENT SYSTEM

7/14/2005 IFT05-fd-safe-principles 13

MENU INGREDIENT HAZARD ANALYSISIngredients Supplier

Makes SafeIngredients Cook

Makes SafeBaked PotatoChicken parts and strips

CharlestonChicken NuggetsChicken Breast

Chicken Fried SteakCod, batteredShrimp, breadedBaconHamburger, Junior and RegularEggs (in-the-shell), over-easy, up,

hard-boiled, poachedSteak

T-boneSirloinCountry Fried Steak

Fresh Vegetables (e.g., Celery, Cilantro, Cucumbers, Onions, Peppers, Lettuce, Romaine, Mushrooms, Tomatoes, Parsley)

Fresh Fruits (e.g., Lemons, Limes, Grapes, Raw Fruit Mix)

CocoaTeasFruit Juices (e.g., orange,

apple, tomato, lemonade)

Soft Drinks (dispenser)Milk (Whole, 2%, skim,

chocolate)CreamAssorted Bread ProductsBagelsBiscuitsApple CrispFrozen Pies (Unbaked and

prepared)Frozen Cakes and

BrowniesOreo Cookie CrumblesIce CreamJams and JelliesSyrups (pancake) Syrups (for malts, sundaes

etc.)Caramel SauceVinegar,Sugar (brown, powdered)Crackers and CroutonsApple Topping

GritsOatmealVegetables, frozenColeslaw MixCanned Fruits (e.g.,

Cranberry and Apple Sauce)

Pico de GalloApplesauce SwimmersTaco ChipsSalsaCheeses (e.g., American,

Swiss, Cheddar, Parmesan, Cream Cheese, Cottage Cheese)

PicklesBBQ SauceCocktail SauceButterMargarineSpreads (Garlic, Sweet

Hickory)HoneySalad Dressings (e.g.,

coleslaw dressing, mayonnaise, tartar sauce, ranch dressing, etc.)

Condiments (e.g., ketchup, mustard)

CreamersCoffees

Mozzarella Cheese SticksPotatoes, parfried

French FriesSkilletHashed BrownsMashed

Onion Rings, parfriedOnion Tanglers, parfriedCorn Beef HashSausage Links, precookedHam Boca BurgerCheese PizzaTurkey Breast, fully cookedSmoked SausageSausage CrumblesNacho MeatRoast BeefEggs, liquid pasteurizedKraft Macaroni and CheeseFrench Toast Batter

(pasteurized ingred.)Pancakes (pasteurized

ingred.)Waffles (pasteurized ingred.)Gravies (pasteurized ingred.)SoupsMarinara SauceWing SauceStuffing

7/14/2005 IFT05-fd-safe-principles 14

PRODUCTS CAN BE GROUPED BY HACCP PROCESSHazards, Critical Controls, Limits (USDA HACCP, 9 CFR 417)

Shelf lifeHACCP Process

Commercially sterile, shelf stable. canned meat, fish, poultry; canned dairy products, canned vegetables

Fully cooked, with inhibitors to make shelf stable. marinara sauce; pie fillings; smoked fish; canned, low-pH fruits and vegetables; dry cereals, pasta

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

Not fully cooked, with inhibitors to make shelf stable. pepperoni; salami; ham; salted, dried fish; cheese; salad dressing; beer; wine

Not fully cooked, not shelf stable. Rare meat, fish, poultry; eggs, vegetables

Not heat treated, with inhibitors to make shelf stable. flour, nuts, salt, sugar, honey, spices and herbs, corn meal, oil and lard

Not heat treated, with secondary inhibitors, not shelf stable.corned beef

Not heat treated, not shelf stable. sashimi; lettuce and coleslaw salads; fruit salads; sprouts; yogurt; sauerkraut; kimchee; salsa

<14 daysI

<14 daysII

>2 years (chem. spoil)

III

<14 daysIV

>2 years (chem. spoil)

V

Hot <4 hoursCold 14-90 days

VI

>5 yearsVII

>5 yearsVII

7/14/2005 IFT05-fd-safe-principles 15

MENU ITEMS GROUPED BY HAZARD AND CONTROL CATEGORIES (Assumes that prerequisite programs are effective.)

7/14/2005 IFT05-fd-safe-principles 16

QUALITY-ASSURED HACCP RECIPE PROCEDURESPreparation time:Prepared by:Supervisor:

Portion size (vol./wt.):Number of portions:Final yield (AS):

Recipe name:Production style:Written by: Date:SA/QA by: Date:

Ingred. #

As Served (weight

Edible Portion (EP) (wt. or vol.)

EP Weight %

Ingredients and Specifications

Gp. #

Ingredients that could produce possible allergic reactions: Prerequisite ProceduresSSOPs / GMPs. Control chemicals. Remove physical hazards from food. Double wash fingertips / personal hygiene (6-log reduction). Sanitize food contact surfaces (5-log reduction). Train. QC. Buy food and store.

Pre-preparation1. Get food for recipe, <3-log increase Listeria monocytogenes (PHF <41ºF).2. Thaw <70ºF. 3. Do pre-prep. No time-temperature hazard. No CCP.

7/14/2005 IFT05-fd-safe-principles 17

QUALITY-ASSURED HACCP RECIPE PROCEDURES (cont'd)

Preparation4. CCP. If making salad with uncooked ingredients, double wash all

fruits and vegetables to reduce vegetative pathogens 2 log.5. CCP. Cook for 5-log Salmonella reduction (155ºF, 15 seconds).

Hold / Serve6. Hot hold, transport, serve. No growth of Clostridium perfringens

(>125ºF).

Leftovers7. CCP. Cool to prevent <1-log increase of Clostridium perfringens

(135 to 41ºF, <14 hours; <2 inches deep or 1-gallon pot).8. Cold hold, <3-log increase Bacillus cereus. If making cold mixed

salad, get all ingredients <50ºF before mixing (PHF <41ºF).9. Throw leftovers away or hold <7 days and reheat to 165ºF, 15

seconds (<3-log increase Bacillus cereus). 10. CCP. For allergen control, do not combine / mix leftovers.

Process step time, hr./min.

End food ctr. temp., ºF

Temp. on / around food

Cover Yes/No

Container size HxWxL

(in.)

Thickest food dimension

(in.)

Start food ctr. temp.,

ºF

Process step #

7/14/2005 IFT05-fd-safe-principles 18

FOOD PROCESS FLOW CHARTING

Industrial Engineering Symbols

= Store (a CCP if other than at end) (1x)S∇

= Inspect (optimize after each CCP) (2x)I�

= Delay/Stage (a CCP, minimize) (1x)DD

= Transport (minimize) (2x)T⇨= Operate (minimize) (12x)OΟ

(CCP = Critical Control Point) Food is made safe to eat

7/14/2005 IFT05-fd-safe-principles 19

FOOD PROCESS FLOW CHARTING (cont'd)

STEP DESCRIPTION CARD

7/14/2005 IFT05-fd-safe-principles 20

CHICKEN CACCIATORE RECIPE HACCP PROCEDURES AND RECORD

7/14/2005 IFT05-fd-safe-principles 21

CHICKEN CACCIATORE HACCP RECIPE FLOW

S=StoreD=DelayT=TransportI=InspectO=operate

7/14/2005 IFT05-fd-safe-principles 22

FOOD ADDITIVESFat SubstitutesSimplessePolydextroseOlestra

AntimicrobialsSaltSugarAcids

Nutritional additives

Texture-improvingGumsStarchesMicrocrystalline celluloseCarboxymethylcellulosePolydextroseAnticaking agentsDough conditionersEmulsifiersHumectantsMeat tenderizers

Nitrates and Nitrites

Sulfites

Irradiation

Indirect additivesProduction aidsAdjuvantsSanitizersPaper board componentsAdhesives and coatingsPolymers

Colors and flavor additivesSugarsHerbsSalt Monosodium glutamate

Color and flavor preservativesAntioxidants

Ascorbic acidBHA BHT Erythorbic acidPropionic acidSodium erythorbateTBHqTocopherols

Chelating agentsDisodium EDTAPolyphosphatesCitric acid

7/14/2005 IFT05-fd-safe-principles 23

INGREDIENTS THAT CAUSE ADVERSE FOOD REACTIONS

Acids AlcoholAntioxidants BenzoatesCaffeine ChiliFood colorings Aza dyesFructose GlutamatesCapsaicin Histamine Nitrates PepperPhenolic substancesSorbitol, natural sugars

Cow's milkLegumes

(includes peanuts)Crustacae, mollusksFishCornEggsWheatTree nuts

Food IntolerancesFood Allergens

The consumers must tell you that they are sensitive.

7/14/2005 IFT05-fd-safe-principles 24

SOME SOLUTES THAT ARE WATER ACTIVITY MODIFIERS

PEG 400LactuloseCitric AcidMaltoseAlanineSorbitolGlycerolNaClGlycine

PEG 600LysineOrnithineTartaric AcidProlineMalic AcidXyloseMannitolUrea

PolydextroseLactoseSucroseDE 42MaltoseGlucose / FructoseLactic AcidPropylene glycolKCl

7/14/2005 IFT05-fd-safe-principles 25

ANTIMICROBIAL ACTIVITY OF SPICES

Black pepper, red pepper, gingerWeak

Allspice, bay leaf, caraway, coriander, cumin, oregano,

rosemary, sage, thyme

Medium

Cinnamon, clove, mustardStrong

SpiceAntimicrobial Activity

Adapted from: Zaika, L.L. 1988. Spices and herbs: Their antimicrobial activity and its determination. J. Food Safety. 9:97-117.

7/14/2005 IFT05-fd-safe-principles 26

ORGANIC ACIDS AND ESTERS FOOD PRESERVATIVES

7/14/2005 IFT05-fd-safe-principles 27

PROCESS QUALIFICATIONA qualified process is one that the cook can demonstrate in operation that all necessary procedures, training, documentation, measurement, controls, and checks and balances are in place to ensure that the process can produce uniform-quality, safe food, even under stress conditions.• Until the performance of the process can be predicted, it is not in

control. To predict, the key process variables must be known, be controlled, and be repeatable.

• Correction – When you find a problem, remove the ROOT CAUSE of the problem.

• A "better" process means:

More stable: Cpk >1; More predictable; Safer =

Common and special causes known; Special causes being reducedWaste being reducedFaster productionBetter customer satisfaction

USL-X3σ

7/14/2005 IFT05-fd-safe-principles 28

PROCESS VALIDATIONPEER-REVIEWED RESEARCH REPORT

[Author(s)]IntroductionWhat is the process; what is the hazard; and what is the purpose of the report?MethodsHow were samples prepared?What microorganisms were used and source?What additives were used?How was the test conducted and controlled?How were the results measured?ResultsWhat were the data from the study, and how uniform were results?DiscussionDiscuss results in terms of the purpose of the studyConclusionsWas or was not the hazard effectively controlled?SummaryDate, Organization

7/14/2005 IFT05-fd-safe-principles 29

SUMMARY• Raw food will always be contaminated. The water and dirt farms

are not sterile. The cook must be able to look at food and decide what needs to be done to make it safe.

• Humans must eat pathogens at a safe level to maintain immune systems.

• Lawsuits for alleged illness will continue to increase. The cook / chef is the person who develops recipes and must be ready to validate and prove that he/she produced a safe food.

• Government retail food inspection does not certify that the foodserved is safe. Inspectors must empower managers and cooks to do self-control and "work themselves out of a job."

• Safe food starts with the menu. The chef must "HACCP" the recipes and train employees to do tasks with zero defects.

• The chef must innovate new process. HACCP is the procedure for self-certification.

• The chef must have a HACCP team and be improving processes and removing problems.