haccp food safety pp11 30 rev10 02

8/3/2019 HACCP Food Safety Pp11 30 Rev10 02

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DESIGNING A FOOD SAFETY PLAN BASED ON HACCP

This manual is adapted from the ServSafe Course Book, Chapter 9, Principles of HACCP System, National Restaurant

Association Education Foundation 1999.


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I. INTRODUCTION: WHAT IS HACCP?

Hazard Analysis Critical Control Point (HACCP) is a system of food safety that treats receiving, storage, prepa-

ration and service of food as a continuous system or flow. Each step is broken down into a logical component

and is evaluated by principles of risk. The premise is simple: If each step of the process is carried out correctly,

the end product will be safe food.

HACCP is based on the principle that if biological, chemical or physical hazards can be identified at any step of

the flow of food, they can be prevented, eliminated, or reduced to safe levels.

Prerequisite programs or Standard Sanitation Operating Procedures (SSOPs) are the basics of serving safe food.

These include checks such as cleaning schedules, use of correct concentrations of chemical sanitizers, and

proper refrigeration temperatures. Section II of this manual describes the SSOPs and provides sample check

sheets for daily, weekly and monthly cleaning and maintenance.

Part of the SSOPs is Employee Training and Personal HygienePolicies. Section III asks basic questions to

consider when developing these policies.

Once the prerequisite standards are complete, the actual menu analysis and flowcharting can begin. Section IV

is a self-help guide to the process steps to take you to HACCP:

Step 1: Assess the HazardsA series of questions focused on the menu

Step 2: Identify Critical Control Points (CCPs)Forms included for a complete flow of potentially

hazardous foods

Step 3: Set up Critical Limits and Standards for CCPsA list of limits and standards included

Step 4: Monitor and DocumentSample forms included

Step 5: Corrective ActionsStep 6: Set up a record-keeping system

Step 7: Verification of the System

Your Food Safety Plan is as individualized as your menu. There are no standard forms that fit all needs. The

examples in this manual can be used in total, modified or redesigned to meet the needs of each individual

operator.

This is not a project that will be completed within a week or two, or even a couple of months. Depending upon

your menu, it could take six months or more. Take your time and train as you go. This is a project that should

include the key people of your food service team. Your Environmental Health Specialist is also available forconsultation.


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II. STANDARD SANITATION OPERATING PROCEDURES (SSOPs)

SSOPs are a prerequisite to the HACCP plan. These are written procedures designed to ensure that unsanitary

conditions do not introduce hazards into the end product. HACCP specifically requires that these procedures

eliminate or reduce hazards from occurring in areas where food is exposed, before and after Critical Control

Points (CCPs) such as cooking, cooling, and re-heating standards have been implemented.

The following questions will assist you in evaluating your current SSOPs and assessing if all areas are ad-

dressed. Additionally, they can serve as a monitoring tool once your SSOPs are in place. Monitoring compli-

ance to your SSOP plan should be conducted at least once per month.

Sample forms of different cleaning schedules can be found in the appendix. Your forms should be designed for

your establishment needs. A schedule provides employee accountability for the completion of the tasks.

The following forms (located in the appendix) are available to help you monitor the SSOPs discussed here:

Weekly Cleaning Schedule

Monthly Cleaning Schedule

Dry Storage and Maintenance

Refrigeration and Food Handling

Handwashing, Warewashing and Cleaning

Master Cleaning Schedule and Sample Cleaning Schedule

Are there established cleaning schedules for maintenance staff and for line staff? (Refer to cleaning sched-

ule located in the appendix.)

Inform everyone: whatis to be cleaned, who is responsible to clean it, when or how often it is to be

cleaned, and how to clean it.

Assign staff member(s) to monitor the cleaning.

(Refer to sample cleaning schedule)

What are the sanitizing standards?

Train the responsible persons

(dishwashers) on the standards

(e.g., final rinse temp on the

dishmachine, or PPM of sanitizers

in the three-compartment sink and

the sanitizing bucket). Develop a

log for dishwashers to record thefinal rinse temp, or the concentra-

tion of chlorine on the machine at

least once daily. Provide instruc-

tions for manual dishwashing

regarding the correct amount of

chemical to use.

Assign staff member(s) to monitor

these readings.


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What are the equipment maintenance standards?

Follow schedules for routine maintenance.

Know how often the exhaust hood and refrigerations condensers are required to be cleaned.

Check thermometers in refrigeration equipment regularly.

Check the cooling equipment routinely and calibrate if necessary.

Check cooking and hot holding equipment routinely and calibrate if necessary.

Operate warewashing equipment according to manufacturers standards.

What are your personal hygiene standards?

Ensure that handwashing facilities are available. Be sure there are

enough for an establishment of your size. Properly equip them with

soap, towels, and nailbrushes. Assign someone to be responsible for

filling the soap and towel dispensers.

Toilet facilities must be accessible and maintained.

Do you have an effective pest control policy?

Are chemicals properly labeled, stored, and safely used?

Contaminants such as lubricants, cleaning compounds, sanitizing agents

and other toxic materials must be stored and used properly.

Food packaging materials and other physical hazards such as broken

glass from light fixtures must be controlled.

III. EMPLOYEE TRAINING/PERSONAL HYGIENE

The following forms (located in the appendix) are available to help you monitor the SSOPs discussed here:

Employee Illness Log

Handwashing, Warewashing, and Cleaning Log

Outline the employee training programs currently in place.

Is an outside trainer needed?

Are there records indicating who attended each training?

Do employees know how to use and calibrate a thermometer?

Are there written personal hygiene standards, including when and how to wash hands?

Are standards given to each employee and do they initial a record indicating they understand?

What is the employee illness policy? The City of Minneapolis enforces the Minnesota Food Code, and it is

specific regarding ill employees (see page 54).

Is there an employee illness log? Minnesota Food Code now requires that a log be maintained for employ-

ees who report of illness involving vomiting or diarrhea.

Has there been MSDS (Material Safety Data Sheets) orientation? Are there logs indicating who attended

and the date? Are sheets accessible by employees?


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IV. CREATING YOUR INDIVIDUALIZED FOOD SAFETY PLAN

CONCEPTS AND DEFINITIONS

Hazards: Biological, chemical, or physical agents that may cause illness or injury if not controlled throughout

the flow of food.

Hazard analysis: The process of identifying and evaluating possible hazards associated with foods in order todecide which foods must be addressed in a HACCP plan.

Control Point (CP): Any step in the flow of food where a physical, chemical, or biological hazard can be

controlled.

Critical Control Point (CCP): The last step where you can intervene to prevent, control, or eliminate a biologi-

cal hazard is before the food is served to customer.

Critical limit: Minimum and maximum limits that the CCP must meet in order to prevent, eliminate, or reduce a

hazards to an acceptable level (e.g., a final cook, hold, or cooling temperatures.)

Monitoring: The process of analyzing whether your critical limits are being met and you are doing things right,

such as taking temperatures at each CCP.

Corrective action: A predetermined step taken when food doesnt meet a critical limit.

Again, here are seven steps to this HACCP-based food safety system.

1. Assess the Hazards. Analyze your menu and assess risks.

2. Identify Critical Control Points (CCPs)

3. Set up Critical Limits and Standards for CCPs

4. Monitoring and Documentation

5. Corrective Action

6. Documentation

7. Verification of your System


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STEP 1. ASSESS THE HAZARDS

A. Analyze your menu.

List potentially hazardous foods and group them into process specific lists: (1, 2, or 3)

1. No Cook StepReceive/Store/Prep/Serve;

2. Food Prep for Same Day ServiceReceive/Store/Prepare/ Cook/Serve; or

3. Complex Food PrepReceive/Store/ Prep/Cook/Hold/Cool/Reheat/Serve.(See example of HACCP Flow of Food Flowchart on the next page.)

The HACCP Flowchart on the next page shows the ways that food flows through an establishment.

Menu Item Process List #

__________________________________________________________ _________________

__________________________________________________________ _________________

__________________________________________________________ _________________

__________________________________________________________ _________________

__________________________________________________________ _________________

__________________________________________________________ _________________

__________________________________________________________ _________________

__________________________________________________________ _________________

__________________________________________________________ _________________

__________________________________________________________ _________________

__________________________________________________________ _________________

__________________________________________________________ _________________

__________________________________________________________ _________________

__________________________________________________________ _________________

__________________________________________________________ _________________

__________________________________________________________ _________________

__________________________________________________________ _________________

__________________________________________________________ _________________

__________________________________________________________ _________________


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HACCP FLOW OF FOOD FLOWCHART

COOLER

RECEIVING

STORING

DRY STORAGECOOLERFREEZER

PREP

COOK

SERVECOOL HOLD

REHEAT

SERVE

PREP

SERVE

REHEAT

COOLSERVE

SERVE


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B. What are the hazards associated with these foods? (See list of hazards on the next page.)

Menu Item Step in the Flow Hazard(s)

__________________________________ _______________ __________________________

_______________ __________________________

_______________ __________________________

__________________________________ _______________ __________________________

_______________ __________________________

_______________ __________________________

__________________________________ _______________ __________________________

_______________ __________________________

_______________ __________________________

__________________________________ _______________ __________________________

_______________ __________________________

_______________ __________________________

__________________________________ _______________ __________________________

_______________ __________________________

_______________ __________________________

__________________________________ _______________ __________________________

_______________ __________________________

_______________ __________________________

__________________________________ _______________ __________________________

_______________ __________________________

_______________ __________________________

__________________________________ _______________ __________________________

_______________ __________________________

_______________ __________________________

__________________________________ _______________ __________________________

_______________ __________________________

_______________ __________________________

This form can be duplicated if needed for large menus.


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IDENTIFICATION OF HAZARDS

BIOLOGICAL

CHEMICALChemical contamination can be caused by pesticides, food additives and preservatives, cleaning and sanitiz-

ing supplies and toxic metals that leach through worn cookware and equipment. Lubricants used for equip-

ment, paints or petroleum products, and personal care items can be contaminated.

PHYSICAL

Including dirt, hair, broken glass, nails, staples, metal fragments, bandaids, and finger cots.

Uncooked Foods

Poultry Products, raw

Red Meats, raw or undercooked

Fish & Shellfish, raw or undercooked

Vegetables, Fruits

(including sprouts, all melons, raspberries,

garnishes, lettuce)

Pathogen

Salmonella, Camplylobacter

Salmonella, E. coli, Campylobacter

Salmonella, Listeriosis, Norwalk Virus,

Diarrhetic Shellfish Poisoning, Vibro

Parahaemolyticus, Anisakiasis Hepatitis A

Norwalk Virus, Shigellosis, Salmonella,

Cryptosporidium, Cyclosporosis

Cooked FoodsMeat, Poultry, Gravy, Sauces

Meat-Containing Soups

Fish & Shellfish

Beans, Rice, Pasta, Cornmeal Dishes

Cooked Vegetables

PathogenClostridium Perfringens, Bacillus Cereus

Staphylococcal Intoxication

Ciguatera Poisoning

Bacillus Cereus (2 forms), Clostridium

Perfringens

Bacillus Cereus

Pesticides

Only your Pest Control Operator should be

applying chemicals.

Additives & Preservatives

Sulfiting agentsMonosodium Glutamate (MSG)

Toxic Metals

Including lead, copper, brass, zinc coating

found on enamelware, or galvanized

containerslead-glazed ceramics.

Foodservice Chemicals


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C. Estimate the risks.

Who is your customer base? Does it include elderly, children, or persons with compromised immune

systems?

D. Who are your suppliers? If required, are they reputable and certified?

E. Do you have the proper equipment and facilities to serve complicated or multi-step recipes? How will you

maintain proper temperatures at each step of preparation?

F. How are your employees trained?

G. Look at the recipe and procedure for the foods you have chosen and fill in the flowchart on the next page.

Make copies and use separate form for each menu item. Refer to HACCP Flow of Food Flowchart on

the previous page for the steps in the process.


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This form can be duplicated for additional food items.

Menu Item Flow Chart

MENU ITEM:

INGREDIENT 1 INGREDIENT 2 INGREDIENT 3 INGREDIENT 4

STEP IN THE FLOW

RECEIVING

Hazard

Standard (CCP?)

Corrective Action

Monitored By

STORAGE

Hazard

Standard (CCP?)

Corrective Action

Monitored By

PREP

Hazard

Standard (CCP?)

Corrective Action

Monitored By

COOK

Hazard

Standard (CCP?)

Corrective Action

Monitored By


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Menu Item Flow Chart (continued)

MENU ITEM:

INGREDIENT 1 INGREDIENT 2 INGREDIENT 3 INGREDIENT 4

STEP IN THE FLOW

COOL

Hazard

Standard (CCP?)

Corrective Action

Monitored By

HOLD

Hazard

Standard (CCP?)

Corrective Action

Monitored By

COOL

Hazard

Standard (CCP?)

Corrective Action

Monitored By

REHEAT

Hazard

Standard (CCP?)

Corrective Action

Monitored By


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STEP 2. IDENTIFY CRITICAL CONTROL POINTS (CCPs)

A Critical Control Point (CCP) is a step in the food flow that will eliminate, reduce or minimize hazards. (The

three hazards of concern are biological, chemical, or physical). Examples of a CCP are cooking, holding,

cooling, and reheating temperatures.

Critical control points differ for each kind of food and method of preparation. Although not necessary at every

stage in the food flow, they are necessary at one or more stages. For example, receiving raw chicken is not aCCP because at this step you would do nothing to eliminate, reduce or minimize the hazards of salmonella or

campylobacter. (Receiving raw chicken would be a CP or control point that would be established to meet your

standards for safety and quality.) Receiving wouldbe a CCP for ready-to-eat foods such as pasta salads, sliced

meats, or raw oysters, and the critical limit would be a temperature of 41F or less.

Return to your flowchart and insert the CCPs.

STEP 3. SET UP CRITICAL LIMITS AND STANDARDS FOR CCPs

A control standard for the CCP is called a critical limit.

v Receiving standards

For all items

All foods received from an approved source

All packaging intact and in good condition

Frozen Foods

Received frozen

No evidence of thawing and re-freezing

No expired use-by dates

Normal color

Normal texture

Dairy products

Receive at 41F or lower, unless otherwise specified by law

Milk: sweetish flavor

Butter: sweet flavor, uniform color, firm texture

Cheese: typical flavor and texture and uniform color

Eggs (shell)

Receive at an air temperature of 45F or lower

Odorless

Clean and unbroken shells

Condition: firm, high yolks that are not easy to break and whites that cling to the yolk


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Raw Meat

Receive at 41F or lower

Beef Color: bright cherry red

Lamb Color: light red

Pork color: pink lean meat, white fat

Texture: firm and springs back when touched

Poultry

Receive at 41F or lower on ice

Color: no discoloration

Texture: firm and springs back when touched

Odor: none

Fish


Color: bright red gills; bright shiny skin

Odor: mild ocean or seaweed smell

Eyes: bright, clear, and full

Texture: firm flesh that springs back when touched

Shellfish (clams, mussels, oysters)



Shells: closed and unbroken (indicates shellfish are alive)

Condition: if fresh, they are received alive

Crustacea (lobster, shrimp, crabs)



Shells: hard and heavy for lobsters and crabs

Condition: if fresh, they must be received alive; packed with seaweed and kept moist

Fresh Produce

Receiving temperatures vary with each produce item

Cut melon is a potentially hazardous food and must be received at 41F or lower

Canned Foods

Can and seal are in good condition

Processed Foods (Modified Atmospheric Packaging (MAP), shrink wrap, etc.)

Refrigerated: receive at 41F or lower, unless specified by the manufacturer

Frozen: frozen foods should be received frozen


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v Storage Standards

Storage areas should be positioned to prevent

contamination.

Keep potentially hazardous food out of the tem-

perature danger zone, 41F to 140F.

Follow FIFO: first in, first out.

Potentially hazardous ready-to-eat foods should be

discarded if not used within seven days of prepara-

tion.

Check the temperature of stored foods and storage

areas regularly.

Store food only in designated storage areas and

store 6 inches off the floor.

Keep storage areas clean and dry.

Keep all goods in clean, undamaged wrappers,packages, or containers that are labeled with date

opened or received, contents, and expiration date.

Clean carts or other vehicles that transport food.

Transfer food between containers properly.

v Pre-preparation standards

Thawing

In a refrigerator, at temperatures of 41F or lower.

Submerged under running potable water, at a temperature of 70F or lower.

In a microwave oven, if the food will be cooked immediately after thawing.

As a part of a cooking procedure, as long as the product meets the required minimum internal

cooking temperature.

Preventing Cross-Contamination

Prepare raw meats, fish, and poultry in separate areas from produce or cooked and ready-to-eat

foods.

Assign specific equipment (cutting boards, utensils, and containers) to each type of food product.

Clean and sanitize all work surfaces, equipment, and utensils after each task.

Make sure cloths or towels used for wiping spills are not used for any other purpose.

Make sure employees wash their hands between tasks.

Consider using single-use disposable gloves when preparing or serving food.

Washing Produce

Wash fruits and vegetables thoroughly under running water before cutting, cooking, or combining

with other ingredients.


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v Preparation standards

Cooking Critical Limits

Poultry: 165F for 15 seconds

Pork: 155F for 15 seconds

Ground or flaked meats: 155F for 15 seconds

Beef and pork roasts: 145F for 15 seconds

Beef steaks, veal, lamb, commercially raised game animals: 155F for 15 seconds

Fish: 145F for 15 seconds

Shell eggs: 145F for 15 seconds

Preventing Cross-Contamination

Prepare raw meats, fish, and poultry in

separate areas from produce or cooked and

ready-to-eat foods.

Assign specific equipment (cutting boards,

utensils, and containers) to each type of

food product.

Clean and sanitize all work surfaces,

equipment, and utensils after each task.

Make sure cloths or towels used for wiping

spills are not used for any other purpose.

Make sure employees wash their hands

between tasks.

Consider using single-use disposable gloves when preparing or serving food.

Washing Produce

Wash fruits and vegetables thoroughly under running water before cutting, cooking, or combining

with other ingredients.

Cold food critical limits

Refrigerate and hold potentially hazardous foods at 41F or lower.


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v Reheating

Reheat food to 165F for 15 seconds within two hours.

Prepare raw meats, fish, and poultry in separate areas from produce or cooked and ready-to-eat

foods.

Assign specific equipment (cutting boards, utensils, and containers) to each type of food product.

Clean and sanitize all work surfaces, equipment, and utensils after each task.

Make sure cloths or towels used for wiping spills are not used for any other purpose.

Make sure employees wash their hands between tasks. Consider using single-use disposable gloves when preparing or serving food.


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STEP 4. MONITORING

The HACCP Daily Temperature Log, and HACCP Time/Temperature Log for Cooling and Reheating Potentially

Hazardous Foods are located in the Appendix.

What critical limits are you measuring?

Who will monitor and how often will it be monitored?

Having CCPs and critical limits are meaningless without monitoring and documentation. Employeesneed training about the importance of monitoring temperatures. They should be involved in estab-

lishing your HACCP system so they understand its importance to your total food safety program.

STEP 5. CORRECTIVE ACTION

When you discover your standards for a critical control point are not being met, it is necessary to take corrective

action immediately.

The type of corrective action will depend a great deal upon your methods of preparation, holding and service.

Analysis of the flowchart will also provide clues. Document the corrective action taken and analyze what

caused the problem and what future actions must be taken to prevent its re-occurrence.

STEP 6. DOCUMENTATION

Forms (HACCP Daily Temperature Log, and HACCP Time/Temperature Log for Cooling and Reheating Poten-

tially Hazardous Foods) are located in the appendix.

Accurate documentation provides a source of information about your daily operations and also shows that your

standards are being met and that you are addressing problems. These records are extremely valuable if a

foodborne illness is alleged or does occur.

Maintain the records in a special book and include flowcharts, SSOPs, and three months of logs.

STEP 7. VERIFICATION OF YOUR HACCP SYSTEM

Each time you add or change the preparation steps of a menu item, revisit your HACCP plan. Review logs to

determine if employees are committed to the plan. You may discover dry lab, or data entries made without

taking actual measurements. This will be an indication that you need to change supervisory techniques, em-

ployee training, or to achieve more personal involvement from your staff.

Ask your district Environmental Health Specialist to review your plan for verification and to provide food code

information or to provide in-house training for your employees.

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