Food Service and Food Service and HACCP…HACCP…

““Perfect Partners Perfect Partners for Food Safety”for Food Safety”

Objectives

• HACCP and its Purpose

• How It Works

• HACCP Principles

• Application to Food Service

• Process HACCP

Definition of HACCPDefinition of HACCP

A systematic approach to the identification, evaluation, and control

of food safety hazards

- NACMCF, 1997

Origin of HACCP• First used by Pillsbury and NASA

in the 60’s.• Alternative to end item product

testing.• Organoleptic inspection did not

guarantee safety.• Cannot test 100% of the product.• 1990s embraced by NACMCF,

industry and regulatory agencies.

HACCP – What It Is

• Hazard Analysis & Critical Control Points

• Is a management tool used to protect the food supply against biological, chemical and physical hazards

• Is preventive, not reactive

HACCP – It’s Purpose

• It is designed to prevent, eliminate and/or reduce, to an acceptable level, all hazards which have a reasonable likelihood of occurrence.

• Hazards may include – foodborne illnesses– physical

hazards/injuries

Current U.S. Foodborne Illness Data(Mead et al., 1999)

• 76 million illnesses

• 325,000 hospitalizations

• 5,000 deaths

Biological HazardsPercentage of Foodborne Illness Attributable to Known Pathogens

V i r u s e s6 7 %

P a r a s i t e s3 %

B a c t e r ia3 0 %

Where Is HACCP Used?

• Global standard for food safety.• Being applied throughout food

industry.• Mandatory for low acid canned

foods (lacf), seafood, red meat, poultry, and citrus juices.

• HACCP for dairy, eggs, sprouts, sushi, retail and restaurant programs are in various stages of development.

HACCP basically is …

• Determining what needs to be controlled and how to control it

• Monitoring what’s important• Determining what can go wrong and

how to “fix it”• Making sure those actions are being

done

How Does HACCP Work

• To be successful must have support and commitment of management.

• Based on seven principles.

How Does HACCP Work

• Still need sanitation and GMPs.– Is not a stand alone program.– Is not zero risk.– HACCP is a work in progress.

• Strategy is to identify significant hazards, assess risk, and develop control.

Seven Principles of HACCP

1. Conduct a hazard analysis.2. Determine the critical control points (CCPs) in

the process.3. Establish critical limits.4. Establish monitoring procedures.5. Establish corrective actions.6. Establish record-keeping and documentation

procedures.7. Establish verification procedures.

Principle 1: Conduct a Hazard AnalysisPrinciple 1: Conduct a Hazard Analysis

• Identify Hazards that warrant control– Likelihood of occurrence = RISK– Severity

HazardA biological, chemical, or physical

agent that is reasonably likely to cause illness or injury in the

absence of its control.

A biological, chemical, or physical agent that is reasonably likely to cause illness or injury in the

absence of its control.

Principle 2: Principle 2:

Determine Critical Control Points (CCPs)Determine Critical Control Points (CCPs)

• Not all steps are CCPs• May be multiple CCPs to address a single

food safety hazard• Last step(s) in a food preparation process

which will control the food safety hazard

CCP A step at which control can be applied and is essential to prevent or

eliminate a food safety hazardor reduce it to an acceptable level.

A step at which control can be applied and is essential to prevent or

eliminate a food safety hazardor reduce it to an acceptable level.

Principle 3: Establish Critical LimitsPrinciple 3: Establish Critical Limits

• Boundaries that define safety• How you know when the CCP is under

control = Measurable/quantifiable• Can be found in the Food Code

ex. Cooking hamburgers CL = 155°F for 15 seconds

Critical Limit

A maximum and/or minimum value to which a biological, chemical,or physical parameter must be controlled at a CCP to prevent,

eliminate or reduce to an acceptable level the occurrence of a food

safety hazard.

A maximum and/or minimum value to which a biological, chemical,or physical parameter must be controlled at a CCP to prevent,

eliminate or reduce to an acceptable level the occurrence of a food

safety hazard.

Principle 4: Principle 4: Establish Monitoring ProceduresEstablish Monitoring Procedures

• Someone needs to keep track of the CCPs• Who is responsible? • How do they do it?• How often do they do it?

Monitoring A planned sequence of observations or measurements to assess

whether a CCP is under control andto produce an accurate record for

use in future verification procedures.

A planned sequence of observations or measurements to assess

whether a CCP is under control andto produce an accurate record for

use in future verification procedures.

Principle 5: Establish Corrective ActionsPrinciple 5: Establish Corrective Actions

• What to do when things go wrong• Keeping unsafe food from the consumer

Corrective Actions

Procedures followed when a deviation occurs.

Procedures followed when a deviation occurs.

Principle 6:Principle 6:

Establish Verification ProceduresEstablish Verification Procedures

• Making sure the whole system is in place and working

• Periodically checking, reviewing, calibrating, etc…• Seeing if the HACCP system needs to be changed.• Includes VALIDATION of the HACCP plan.

Verification Activities, other than monitoring, that determine the validity of the HACCP

plan and that the system is operating according to the plan.

Activities, other than monitoring, that determine the validity of the HACCP

plan and that the system is operating according to the plan.

Principle 7: Establish Record-keeping Principle 7: Establish Record-keeping and Documentation Proceduresand Documentation Procedures

• Provide documentation that the critical limits at each CCP were met or that the appropriate corrective actions were taken when not met

• Provide documentation that the actions performed were verified and were consistent with the HACCP

“...intended to assist industry’s voluntary implementation of HACCP principles.”

Retail HACCPRetail HACCP

Draft Retail HACCP Guide

www.cfsan.fda.gov/~ear/retail.html

Food Service Industry Vs. Processing Industries?

• Food Service not defined by specific commodities.

• Many different ways of making the same menu item, e.g. using precooked chicken Vs. raw chicken in a chicken salad recipe.

• Diversity among food service facility types, design and construction.

Defining Food Service HACCP

Application of HACCP Principles

• Active Managerial Control of Risk Factors

• Flexible

• Process-specific

Building Your Food Safety Management

System

Group menu items into

1 of 3 prep processes

Food Service HACCP

Considerations with ALL Processes:

• No bare hand contact with RTE food

(or approved, alternate procedure)• Proper Handwashing• Datemarking• Restriction or exclusion of ill employees

Food Service HACCP

Considerations with ALL Processes:

• Separation of raw animal foods with RTE foods to prevent cross-contamination

• Prevention of cross-contamination of RTE food or clean and sanitized food contact surfaces with soiled cutting boards, utensils, aprons, etc.

Receive Store Prepare Hold Serve

Examples: Tuna Salad, Sandwiches, Green Salads, Chicken

Salad

Food Service HACCPFood Service HACCP

Process #1: Preparation of RTE Food with No Cook Step

Food Service HACCP

Considerations with Process 1• There is no cook step.• Focus on:

– cold holding or time alone– food source (esp. shellfish and fish)– receiving temps (esp. finfish)– freezing to destroy parasites

• Be flexible - Not every flow will be “textbook”

Receive Store Prepare Cook Hold Serve

Examples: Fried Shrimp, Macaroni & Cheese, Mashed Potatoes

Food Service HACCPFood Service HACCP

Process #2: Preparation for Same Day Service

Food Service HACCP

Considerations with Process 2

• Food will pass through the danger zone only once.

• Focus on:– Cooking– Hot holding or using time alone

Receive Store Prepare Cook

Cool Reheat Hot Hold Serve Examples: Beef Stew, Soups, Gravy, Chili

Food Service HACCPFood Service HACCP

Process #3: Complex Food Preparation

Food Service HACCP

Considerations with Process 3• Pass through the danger zone more than

once.• Focus on:

– Cooking– Cooling– Hot and cold holding or using time alone– Reheating

41o F

140o F

Danger Zone Diagram

COOK COOL REHEAT

11 22 33

Times through the Danger Zone

Complex Food PrepSame Day Service

Procedural Step 1Develop Prerequisite

Programs

• Procedures that address basic operational and sanitation conditions in an establishment

• Examples:– Vendor certification programs– Training programs– Recipe/Process instructions– Standard Operating Procedures (SOPs)

Group your Menu Items/Products

•Process #1 – Food preparation with no cook step

•Process #2 – Food preparation for same day service

•Process #3 - Complex Food

preparation

Procedural Step # 2

Conduct a Hazard Analysis

Procedural Step # 3

1 Identify Hazards of Significance

2 Assess the Risk and Severity of the Hazards

3 Determine the Control Measures that May be Taken to Ensure that the Hazards are Controlled

3 Steps to Conducting a Hazard Analysis . . .

Identifying Hazards of Significance

Consider . . .

• Ingredients, processing, distribution and

intended purpose• Current research and epidemiology• Foods within the same food prep process will

have similar hazards

Assessing Risk and Severity

Norwalk-like virus

C. botulinum

SEVERITY

R ISK

General Categories of Hazards

• Biological– Bacterial, viral, parasitic contamination– Bacterial growth– Bacterial toxin production– Bacterial, parasitic, or viral cross-contamination

• Chemical– Contamination– Scombroid toxin– Ciguatera

• Physical − Glass−Metal−Rocks−Plastic

Procedural Step # 4

Implementing control measures

and

Establishing critical limits

Determining Control Measures

• Actions or activities that can be used to prevent, eliminate, or reduce a hazard

• Examples: cooking, implementing an employee health policy, proper handwashing, preventing cross-contamination

Determining critical limits

• Are usually established by a regulatory standard (Food Code)

• Measurable and quantifiable

• Can be tailored to a particular operation

PRODUCT: RAW HAMBURGER PATTY CCP: COOKING (WELL)

Examples

PRODUCT: REFRIED BEANS CCP: REHEATING

PRODUCT: BEEF CHILI CCP: COOLING

CL:

CL:

155ºF for 15 seconds

6 hours from 140ºF to 41ºF and 140ºF to 70ºF within the first 2 hours

165ºF within 2 hours

CL:

Procedural Step # 5

Establishing

Monitoring Procedures

Definition of monitoring

The act of observing and making measurements to help determine if critical limits are being met and maintained

• Visual observations

• Temperature

• Time

• pH

• Water activity

Examples of Monitoring

Consider the following . . .

• What you will monitor

• How you will monitor

• When and how often you will monitor

• Who will be responsible for monitoring

Who monitors

• Directly associated with the operation• Trained and knowledgeable• Accessible to monitoring activity• Responsible

Procedural Step # 6

Develop Corrective Actions

Purpose of Corrective Actions

• To correct cause of deviation

• To determine proper disposition of affected food

• What measures do you expect employees to take to correct the problem?

• Do your employees understand the corrective action?

• Can the corrective action be easily implemented?

Deciding on Corrective Actions

• Conduct On-Going Verification– Verification is and oversight auditing process to

ensure that the HACCP plan and SSOPs continue to be adequate and consistently followed.

Procedural Step 7

• Observing the person doing the monitoring – is it being done as planned

• Reviewing monitoring Records

• Checking Corrective Action Reports

• Periodically reviewing the total plan

• Test product in process

• Review equipment calibration records

On-going Verification activities include

• Record Keeping –

• A record keeping system can be simple and needs to be designed to meet the needs of your operation

• Accurate record keeping is an essential part of a successful HACCP Program

Procedural Step 8

5 Types of Records

1. Records related to prerequisite programs

2. Monitoring records

3. Corrective actions records

4. On-going verification and periodic validation records

5. Calibration records

Procedural Step 8

Take into consideration…

• Simple records are easier to maintain

• How are records maintained

• Who is responsible for record maintenance

• How long will the records be kept

Procedural Step 8

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Thank you